Pump communication module, pump system using same and methods related thereto

ABSTRACT

A pump system comprising a primary AC pump, a control unit having a wireless communication module, and a back-up battery for powering the control unit. The wireless communication module is configured to communicate via a primary wireless connection and communicate via a secondary wireless connection. Additional pump system components and various methods relating to same are further disclosed herein.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No.62/433,772, filed Dec. 13, 2016, and U.S. Provisional Application No.62/597,407, filed Dec. 11, 2017, both of which are hereby incorporatedherein by reference in their entirety.

FIELD OF TECHNOLOGY

The present disclosure generally describes a pump communication circuitor module, a pump system using same and methods relating thereto. Morespecifically, the present disclosure describes pump systems that have asecondary or redundant communication method, sump pumps that integrate abackup battery powered pumping system and a controller that providesstatus notification options via the redundant communication setup, aswell as related methods.

BACKGROUND

Sumps are low pits or basins designed to collects undesirable liquidssuch as water around the foundation of a home. Water that seeps into thehome from the outside can flow into the sump to prevent water fromspreading throughout the home. If too much water seeps into the sump, asump pump can be employed to move the water from the sump to a locationoutside the house.

A typical electric basement sump pump includes a pump to remove waterfrom the sump basin, and various switches and related components thatturn the pump on and off when appropriate, based on the water levels inthe sump. Electric sump pumps are generally powered via an AC powersource that plugs into a home's AC power supply.

Sump pump systems can also be equipped with audible alarm and/or usernotification systems that transmit messages via text, e-mail, or a phonecall to a user in the event of pump malfunction, power outage, or highwater (flooding) conditions. Unfortunately, these systems are prone tofail during the most critical times, such as when line power (or mainspower) is lost. Thus, a need exists for pump components, systems andmethods that address this issue.

SUMMARY

The present disclosure describes a pump communication circuit or modulethat allows for redundant communication, sump pumps that integrate abackup powered sump pump system into a primary powered sump pump andutilize such a communication circuit or module and methods relating tosame. The present disclosure also describes sump pumps that integratecontrol and notification systems that determine when to activate thebackup DC powered sump pump system, and notify home owners regarding theoperating status of the integrated pumping system. In addition tovarious exemplary embodiments, the present disclosure further coversmethods related to the aforesaid embodiments.

BRIEF DESCRIPTION OF THE DRAWINGS

Described herein are embodiments of systems, methods and apparatus foraddressing shortcomings of known sump pumps.

This description includes drawings, wherein:

FIG. 1A shows an isometric view of an example tandem sump pump assemblydescribed herein.

FIGS. 1B and 1C show front and rear elevation views, respectively, ofthe tandem sump pump assembly of FIG. 1.

FIGS. 1D and 1E show right and left elevation views, respectively, ofthe tandem sump pump assembly of FIG. 1.

FIGS. 1F and 1G show top and bottom plan views, respectively, of thetandem sump pump assembly of FIG. 1.

FIG. 2A shows an example of a tandem sump pump assembly connected to adischarge pipe with an integrated control/power module.

FIG. 2B is an up close view of the tandem sump pump assembly of FIG. 2A.

FIG. 3 is a diagram demonstrating various functionality of an integratedsump pump control and battery charging system described herein.

FIGS. 4A-B are sketches showing an example of a sump pump in a sump pitwith a pressure tube.

FIGS. 5A-B show examples of a warning notification and communicationsystem described herein.

FIG. 6 shows a top view of an exemplary configuration of a twin volutecomponent of a tandem sump pump assembly.

FIG. 7 is an example of a conventional DC powered backup sump pump.

FIG. 8 is a schematic diagram of an example control system for a tandemsump pump system described herein.

FIG. 9 is a schematic diagram of a dual processor redundant backupsystem for a sump pump system described herein.

FIG. 10 is a schematic diagram of an alternate example of a redundantcontroller system as described herein.

FIG. 11A is a schematic drawing of a redundant control system for a dualsump pump arrangement utilizing a processor and a software-free relaycontroller in accordance with examples described herein.

FIG. 11B is a more detailed schematic of a redundant control system fora dual sump pump arrangement utilizing a processor and a dual switchsoftware-free relay controller in accordance with examples describedherein.

FIG. 11C is a sketch of a redundant switch used in accordance withexamples of redundant control systems described herein.

FIG. 12 is a schematic drawing of a system that allows two separatepumping systems to communicate with one another in accordance withexamples described herein.

FIGS. 13A-G show various views of an alternate exemplary tandem sumppump assembly with cross-over piping and associated check valvesextended at a height above the sump pumps and/or above the sump pit inorder to simplify service of same in accordance with examples describedherein.

FIG. 14 is a bottom view of an exemplary embodiment of a sump pumpassembly where the two sump pumps are of different sizes in accordancewith examples described herein.

FIG. 15 shows an example of a tandem sump pump system that utilizes twoseparate discharge lines without a crossover pipe in accordance withexamples described herein.

FIG. 16A shows an exemplary sump pump assembly with a bracket that cuffsthe two pumps together in accordance with examples described herein.

FIG. 16B shows the bracket of the assembly of FIG. 16A having a bridgedconfiguration to support a pressure tube.

FIG. 17 shows an example of a flat, or planar bracket that could be usedin accordance with a sump pump assembly described herein.

FIG. 18 shows an example of a pressure tube housing used in accordancewith examples of sump pump systems described herein.

FIG. 19A shows an example of a sump pump system utilizing check valvesfor demonstrative purposes.

FIG. 19B shows an example of a sump pump system without check valves fordemonstrative purposes.

FIG. 20 shows an example of a sump pump assembly utilizing separatecheck valves for each pump in accordance with examples described herein.

FIG. 21 shows an example of a dual sump pump system with an isolationvalve in accordance with aspects described herein.

FIGS. 22A and 22B show a cross section of an isolation check valve invarious states of operation in accordance with examples describedherein.

FIG. 23 shows a cross section of one example of an isolation valvedescribed herein.

FIG. 24A shows another example of an isolation valve, and FIGS. 24B-Dshow cross sections of the isolation valve of FIG. 24A in various statesof operation accordance with other examples described herein.

FIG. 25A shows an example of a sump pump system with a redundant highwater switch in accordance with aspects described herein.

FIG. 25B shows the sump pump system of FIG. 25A, with a cover of thehigh water switch removed to show the internal components of the highwater switch.

FIG. 26 shows a configuration of a dual pump assembly incorporating astrap handle in addition to other features described in the examplespresented herein.

FIG. 27A shows a dual pump assembly with an air switch and a one-piecedischarge pipe in accordance with examples described herein. FIG. 27Bshows a bracket of the dual pump assembly of FIG. 27A in more detail andseparate from the assembly.

FIG. 28 shows a remote display panel for a pumping system that providessystem status and water level information in accordance with examplesdescribed herein.

FIG. 29A is a top view of an integrated pump controller and batterymanagement system in accordance with examples described herein.

FIG. 29B is a rear view of the integrated pump controller and batterymanagement system of FIG. 29A.

FIGS. 30A and B show an example of a tilt switch utilizing anaccelerometer in accordance with examples described in this application.

FIG. 31 shows an example pumping system employing a sump pump and thetilt switch of FIGS. 30A and B.

FIGS. 32A and 32B show various views of an integrated pump controllerand battery management system in accordance with examples describedherein.

FIG. 33 shows a multi-pump system having a connector for connecting twopumps in accordance with examples described herein.

FIG. 34A shows a simplified network diagram over which a pumpcommunicates in a first state.

FIG. 34B shows a simplified network diagram over which a pumpcommunicates in a second state.

FIG. 35A is an exemplary flow chart illustrating setup or installationof the pump communication system of FIGS. 34A-34B.

FIG. 35B is an exemplary flow chart illustrating operation of the pumpcommunication system of FIGS. 34A-34B after setup.

FIGS. 36A-36Q are screenshots of a software application interface foroperating and/or communicating with a pump system described herein, withFIGS. 36A-36F relating to initial installation or setup of the system bya professional installer, FIGS. 36G-36H relating to setup andregistration by a home owner, FIGS. 36I-36K relating to normal operationof the system with a Wi-Fi internet connection present, FIGS. 36L-36Orelating to operation of the system when Wi-Fi internet connection islost, FIG. 36P relating to a notice provided when regular Wi-Fi internetis available while in Soft AP direct connection mode and FIG. 36Qillustrating an example of what the screen display would look like ifregular Wi-Fi internet is available but the AC pump went offline forsome reason.

FIG. 37A illustrates a pump system having a wireless communicationmodule and a remote display.

FIG. 37B illustrates the wireless communication module of the pumpsystem of FIG. 37A.

Corresponding reference characters in the attached drawings indicatecorresponding components throughout the several views of the drawings.In addition, elements in the figures are illustrated for simplicity andclarity and have not necessarily been drawn to scale. For example, thedimensions of some of the elements in the figures may be exaggeratedrelative to other elements to help to improve understanding of variousembodiments. Also, common but well-understood elements that are usefulor necessary in a commercially feasible embodiment are often notdepicted or described in order to facilitate a less obstructed view ofthe illustrated elements and a more concise disclosure.

DETAILED DESCRIPTION

Sump pumps are often most useful during storms. That is because stormsbring in large amounts of water that can lead to flooding. However,storms can also result in a home losing power. In such a situation, anAC powered sump pump will be unable to operate. Accordingly, forsecurity purposes, home owners also install a battery back-up systemthat can supply power to a DC pump to remove water from the sump basinin the event of an AC power outage or primary pump malfunction.

Such a battery back-up system may include a DC powered pump to removewater from the sump basin, float level switches and related componentsto turn the pump on & off based on water levels, and a 12-volt DCbattery with a charging system and related electrical connections. Anexample of such a conventional pump 700 is shown in FIG. 7.

Combining a primary AC powered sump pump system with a separate backupDC powered sump pump system can present several drawbacks. For example,as the complexity of these primary & back-up pump systems increase, theoverall reliability can be impacted by the number of switches andelectrical connections.

Additionally, the ability of the system to transmit messages duringpower outages can be compromised or limited in function, as thenotification systems generally rely on home functionality (e.g., landline circuits) that are also inoperable during power outages. Thus,these systems cannot take advantage of the latest communicationtechnologies.

Further, sump systems with two pumps and multiple float switches areoften too large to fit into the smaller diameter sump pits found inolder homes. As a result, such homes with smaller sump pits are not ableto take advantage of the benefits of a conventional backup DC sump pumpsystem or require homeowners to purchase items to help place the pumpsin a staggered manner in the sump pit which is not convenient.

The present disclosure describes sump pumps that integrate a backup DCpowered sump pump system into a primary AC powered sump pump. Thepresent disclosure also describes sump pumps that integrate control andnotification systems that determine when to activate the backup DCpowered sump pump system, and notify home owners regarding the operatingstatus of the integrated pumping system. Still further, the presentdisclosure also describes a redundant pump communication system thatallows a home owner or pump user to continue to have communication witha pump even when the primary means of communication is not available(e.g., such as when a storm knocks out power to a home disrupting itsnetwork operations). For example, a pump communication system isdisclosed that utilizes a remote electronic device's own wireless accesspoint technology to form a hotspot that the pump communication modulecan tether to so that the pump is capable of communicating even if theprimary communication circuit (e.g., a wireless network circuit) is downdue to a problem with the primary communication network or itscomponents (e.g., router, modem, etc.). In this way, the system forms asecondary or redundant communication technique for the pump to use tomaintain communication while the primary communication technique isunavailable.

FIG. 1A shows an isometric view of an example tandem sump pump assembly100. As shown in the Figure, the sump pump assembly 100 includes a firstpump 120 and a second pump 130. FIGS. 1B-G show front, rear, right,left, top, and bottom views of the tandem pump assembly 100,respectively.

In the form shown, the first pump 120 is a primary pump powered via anAC power supply 102 and the second pump 130 is a backup pump powered bya DC power supply 104, such as a battery. However, it should beunderstood that in alternate embodiments the pumps can be setup in anydesired configuration. For example, in some embodiments, pump 130 couldbe the primary AC pump and pump 120 could be the backup DC pump. Inother embodiments, both pumps 120 and 130 could be AC pumps powered viaan AC power supply, or DC pumps powered by a DC power supply. In stillother embodiments, pumps 120, 130 could be any combination of AC/DCpumps desired.

Turning back to the embodiment illustrated in FIGS. 1A-G, in a preferredform, the system 100 includes two separate check valves 161 and 162 thatinhibit backflow into each of the separate pumps, but that ultimatelydischarge into a common discharge outlet 160. In addition, the pumpassembly comprises a twin volute 110, that serves as the volute for bothpumps 120, 130 of the assembly. In some examples, the twin volute 110comprises two separate volutes 111 and 112 (e.g., one for each pump)that are not in fluid communication with one another as shown in FIG.1G. In some examples, the twin volutes 111 and 112 can be arranged in aspace saving and attached configuration as shown in FIG. 1G. In thisform, the volutes 111, 112 are shown to have a “yin-yang” configuration(or semi-yin-yang configuration), which allows the pump to save space.This space saving configuration allows the assembly 100 to fit intosmaller sump pits. In some examples the volutes 111 and 112 may besimilar or even identical in size. In other examples, one volute (e.g.,volute 112) may be larger or even significantly larger than the other aswill be discussed further below regarding alternate embodiments.

While the embodiment shown in FIGS. 1A-G illustrate the volutes beingconnected to one another to make the tandem system 100 easier to placein the sump pit together as a stable assembly, it should be understoodthat in alternate embodiments the pumps and pump components may beconfigured so as not to be connected to one another except by the commondischarge piping to simplify servicing so that one pump may be removedand worked on or replaced without requiring removal of the other pump,if desired (which will also be discussed further below regardingalternate embodiments).

Turning back to the embodiment illustrated, FIG. 1G shows the twinvolute 110 as two separate volutes 111 and 112 that are separable fromone another, but interconnected or connected to one another via afastener or connector. That is, they are not formed as part of a singlepiece, but are instead held together by way of a fastener or connector.In alternate forms, the volutes may be held together with assembly 100via attachment to the pump assembly 100 (e.g., via attachment to theirrespective pumps which are then connected to one another via the commondischarge piping). Pads 115 a-f on the bottom surface of the twin volutecan help support the stability of the system 100. In some embodiments,however, the twin volute 110 can be a single piece that may be formed,for example, from a single molded or cast material. FIG. 6 shows anexample of a twin volute 610 formed as a single component.

In some examples, the independent volutes 111/611 and 112/612 of thetwin volute 110/610 are not in fluid communication, even if the volutesare formed as a single component, as shown in FIG. 6. That is, they arediscrete or individual volute chambers or fluid passages with no fluidpath connecting the two volute chambers or fluid passages. In otherexamples, however, the twin volute 110/610 may include a single orcommon volute chamber or fluid passage such that the volute for each ofpumps 120 and 130 are one in the same or at least in fluid communicationwith one another.

Referring again to FIGS. 1A-G, the assembly 100 includes an integratedhandle 140 that allows for both pumps to be carried together, andlowered into a sump or a pit in a basement. This integrated handle 140allows for easy installation or simplified out-of-box drop-in setup. Ina preferred form, the handle 140 works together with the commondischarge piping to interconnect the pumps 120, 130 so that the systemcan easily be installed or removed as one assembly.

As mentioned above, in a preferred form, the assembly 100 has a singledischarge outlet 160, such that each of the first pump 120 and thesecond pump 130 pump fluid toward the common discharge outlet 160. Thedischarge outlet 160 can connect to a discharge pipe via a check valve.Because the assembly utilizes one discharge outlet for two pumpingunits, the assembly can be installed in a quicker manner. That is, aninstaller need only connect a discharge pipe to a single outlet, whichcan save considerable time in the installation process. Each pump 120and 130 can pump fluid toward the discharge outlet 160 throughrespective check valves 161 and 162, which are connected via cross-overpiping 165. Thus, this discharge piping helps interconnect the pumps120, 130 to one another so that they may be placed as an interconnectedassembly.

In some aspects, the discharge outlet 160, cross-over piping 165, andcheck valves 161 and 162 can be moved higher up above the sump pumps 120and 130. For example, some embodiments may utilize a length of tube orpipe such that check valves 161, 162, and discharge outlet 160 areraised higher, so that they extend out of the sump pit. FIGS. 13A-Gpresent an example of a tandem sump pump assembly 1300 with cross-overpipe 1365 extended at a height above the sump pumps 1320 and 1330 andabove the sump pit. For example, discharge outlet 1360 and the two checkvalves 1361 and 1362 are elevated far above the assembly and connectedvia a crossover 1365 pipe significantly above the sump pumps 1320 and1330 when compared with the embodiment of FIGS. 1A-G. That is, thecross-over pipe 1365, the primary pump check valve 1361, and thesecondary pump check valve 1362 are positioned at a height sufficientlyhigh above the primary 1320 and secondary pumps 1330 so that when thetandem sump pump unit 1300 is placed in a sump pit, the primary pumpcheck valve 1361, and the secondary pump check valve 1362 are accessiblefor maintenance and repair without having to enter the sump pit orremove the tandem sump pump unit from the sump pit. In this manner, anoperator can effectively disconnect one pump from outside the sumpwithout having to turn the system off, as the check valves will be morereadily within reach. That is, within reach from outside of the sump pitwithout having to enter the pit, or without having to remove both pumpsfrom the sump pit. One pump can be thus replaced and/or repaired whilethe other pump continues to operate. That is, one pump can bedisconnected from the system and then pulled up from the sump while theother pump continues to operate. In such embodiments, the assembly 1300may employ separate or dis-connectable volutes rather than the commonvolute 1310 described above.

FIG. 15 provides another example of a tandem sump pump system 1500 thatutilizes two separate discharge lines 1660 a and 1660 b without acrossover pipe. That is, the pump system 1500 includes a first pump 1520and a second pump 1530 that each utilize a separate discharge line 1560a and 1560 b, respectively. In this example, unlike that of FIGS. 13A-G,no crossover pipe connects the primary check valve 1561 and thesecondary check valve 1562 to direct the pumped fluid to a commondischarge line. Instead, each pump 1520 and 1530 pumps toward its owndischarge outlet. This dual outlet configuration provides redundancyadvantages in that, if one discharge line becomes clogged or blocked bydebris, vermin, or the like, the other discharge outlet will remainoperational. Further, employing separate discharge lines allows thesystem to omit the individual check valves, if desired (e.g., primarycheck valve 1561 and secondary check valve 1562 can be optional). Thiscan provide added cost savings and a simplified design. Additionally,using separate discharge lines as shown in FIG. 15 can reduce systempressure drop, which allows the pumps to operate at a higher flow rate.In some examples, the check valves 1562 and 1561 (along with othercomponents) can be made from stainless steel. In other examples, thecheck valves can be made from a plastic material or other metals.

In FIGS. 1A-G the sump pumps 120 and 130 are generally depicted as beingthe same size. It is contemplated that in some embodiments the sumppumps can be different in size, shape, or operation. FIG. 14 is a bottomview of an example sump pump assembly 1400 with such a configuration.That is, the first sump pump volute 1411 (which can be, for example, aprimary pump, such as an AC powered pump) may be larger than the secondsump pump volute 1412 (which can be, for example, a backup pump, such asa DC powered pump). It should be understood that smaller volutes aretypically associated with smaller pumps and smaller pump housings.Accordingly, it should be understood that the assembly 1400 of FIG. 14could include two pumps of different sizes.

FIG. 2A shows an example of a tandem sump pump assembly 200 connected toa discharge pipe 270 via check valves 261, 262 (262 is not shown, but issimilar in type and location to check valve 162). FIG. 2A shows anexpanded view that includes an integrated control/power module 280. FIG.2B is an up close view of the tandem sump pump assembly of FIG. 2A. Asshown, a rubber coupling connects the discharge outlet 250 of theassembly 200 to the discharge pipe 270, and is secured via conventionalhose clamps. This configuration allows the assembly 200 to be placed inthe sump pit and then secured to existing plumbing if needed. However,in alternate embodiments, the discharge piping may be configured in avariety of different ways (see an exemplary embodiment of this in FIG.13A which will be discussed later).

As shown in FIG. 2A, the system also includes a control/power system280. In some examples the control/power system will be an integratedmodule, as shown in the embodiment of FIG. 2A, where the control circuitand power circuit are included as a part of the same component. In otherforms, the control circuit and power circuit may be integrated into acontroller further removed from the sump pit area, such as the controlunit 510 illustrated in FIGS. 5A-B. This integrated design moves thepump motor switch operation “out of the water”, thereby increasingreliability. That is, because the sump control system enclosure can alsoaccommodate the battery charging electronics, the charging componentsare moved away from the harsh environment of the battery box and into anarea more convenient for viewing & operation by the home owner. This canbe useful, for example, for sealed sump units with Radon abatementsystems. The lower profile of the pump embodiment of FIGS. 1A-G (ascompared to the high crossover/easy servicing embodiment of FIGS. 13A-G)may also be more desirable in such sealed sump units because of theability to contain the tandem assembly within the sealed pit.

In other embodiments, the power controller and the communication modulemay be separate modules, so that either module can be removed,uninstalled, replaced or otherwise separately provided from the othermodule. For example, in FIGS. 5A-B, a system is illustrated havingseparate control and communication modules. By offering a separatemodular arrangement, the system can take advantage of improvements inpower and/or communication technologies, without requiring replacementof the other power/communication equipment. Moreover, theinterchangeability of the power and control systems allows the systemsto be adapted for different pumps and equipment that may operate ondifferent power configurations. For example, with this configuration thesystems can be adapted to be used with 10 amp pumping systems, or 4 amppumping systems, or other pumping systems having differing operatingparameters or employing various different electrical configurations. Inyet other forms, the system may be configured with separate pumpcontrol, power control and communications modules so that any of thesemodules may be repaired, replaced or updated without requiring change tothe other modules.

Returning to the embodiment of FIGS. 2A-B, the integrated control/powersystem 280 can include a central control system, (also referred to as acontroller) in electrical communication with the sump pump system (e.g.,systems 100 or 200 of FIGS. 1A-B and 2A-B). That is, the controller canbe in electrical communication with a primary sump pump that is poweredby an AC power supply and a backup sump pump that is powered by a DCpower supply. Via the controller, the control/power system 280 can beconfigured to control operation among the primary sump pump and thebackup sump pump. Again, as mentioned above, the system could be setupto use two DC pumps or two AC pumps as desired, however, in a preferredform, the system will be configured with at least one DC pump, whichwould be needed for power outages as discussed above.

The control/power system 280 also includes a charging module configuredto charge the DC power supply and a battery that provides power to thepump system in the event of a power outage to the home. The chargingmodule can operate to charge the battery when AC power is on to ensurethat the battery is fully charged in the event of a power outage orother problem with the AC power source.

In some forms, the controller can serve as the controller for the entiresump pump system. In other forms, different controllers may be used fordifferent responsibilities or, alternatively, may be setup in aredundant manner as will be discussed further below. In still otherforms, other fallback designs may be used to help the system operate atleast in a minimal capacity even if the controller fails. These will bediscussed further below with respect to other embodiments.

FIG. 3 is a diagram demonstrating various functionality of an integratedsump pump control and battery charging system 300. In some examples, thesystem 300 is connected to an AC power source 310 (e.g., a 120V poweroutlet) and, thus, includes an AC input (e.g., a power cord and plug,etc.), a DC power source 320 (e.g., a battery or battery hookup), or acombination of both. Fluid level inputs can be supplied by single ormultiple input mechanisms such as float switches 330, relativedisplacement (tilt) switches, pneumatic pressure switches 340 (e.g.,probe tubes) or the like. In the form illustrated, the auxiliary floatswitch 330 is meant to connect to a high water float switch or waterlevel sensor to identify a high water or flood condition via display355. In this way, the auxiliary float switch 330 serves as a redundantfluid level sensor to back up the pneumatic pressure tube sensor 340.The system 300 can also include an audible alarm 360 that can be used toproduce a signal or warning. For example, audible alarm 360 may includea speaker arrangement, a buzzer, a siren, a beeping device, or the like.In some forms, the controller or system 300 further includes an outputto connect to a home security system to trigger an alarm or notificationcondition via the home security system.

In some forms, the system 300 may include an interface 350 that displaysinformation pertaining to the operating status of the system. Forexample, the interface 350 may display information pertaining to thewater level 351, the battery status 352, and the operation status of thebackup pump 353 or main pump 354. The interface 350 may also includehigh water warning icons 355, battery fault icons 356, or controlswitches that execute functionality, like a system test switch 357(e.g., that activates a system test protocol) and a buzzer switch 358(e.g., that shuts off or mutes a buzzer). In the form illustrated, thevisual displays 351, 355, 353, 356 and 354 coincide with the inputs 340,330, 370, 320 and 380, respectively, and utilize colors to relayinformation regarding system status or water status. For example, greencolors appearing in conjunction with the water level sensor 351, back-uppump indicator 353, battery indicator 356, and main pump indicator 354indicate the system is running properly. Conversely, red colorsappearing in conjunction with water level sensor 351, high waterindicator 355 and battery fault and state indicator 356 indicate apotential or current problem with the system (e.g., low battery, nobattery, etc.) or undesirable high water level situation. In the formillustrated, the system 300 is setup modularly so that system 300 servesas the pump controller and nearby notification module, but is alsoconnected to a communications or remote notification module to providefurther notification to remote locations such as remote user locationsvia an analog or digital auto dialer unit, a cellular or digitalnotification unit, etc. FIG. 3 depicts some exemplary data that may becommunicated between the communications module and system or controller300 such as AC system power status, water level, alarm conditions, DCsystem power status, battery state, pump operation, pump cycle count,system failures and remote diagnostic or testing features.

Some examples described herein may employ a controller that monitors andassesses battery state of health, and/or battery state of chargeproperties. Conventional battery test methods for pumping devices ofteninvolve discharging, or at least partially discharging the battery. Butthis can cause problems, in particular, with how power or heat generatedduring the test is dissipated. Accordingly, certain aspects describedherein may employ battery testing and assessment techniques that useconductance measurements. Conductance describes the ability of a batteryto conduct current. At low frequencies, the conductance of a battery isan indicator of battery state-of-health showing a linear correlationwith a battery's timed-discharge capacity. Accordingly, informationobtained from the conductance test can be used as a predictor of batteryend-of-life. In one aspect, a controller may be equipped to utilizesimilar operating software that is used to test equipment related toother industries, such as automotive equipment, and may also useadvanced monitoring systems that are associated with stationary powerapplications. That is, the testing algorithms used to monitor theseother types of equipment could be incorporated into a control board ofthe controller. In this manner, the present controller can useconductance testing of the battery to determine state of health and/orstate of charge, which has not been utilized in conventional batteryback-up sump systems.

The present disclosure also describes warning and communication systemsused in connection with pump systems. FIGS. 5A-B show examples of awarning notification and communication system. FIG. 5A shows an expandedview that includes a system controller such as notification module 510and a communication module 520, and FIG. 5B shows a close up view of thenotification module 510. As shown, the notification module 510 comprisesa series of LED lights 512 n that light up to indicate warnings or otherinformation. For example, the LED lights 512 can represent operation ofthe backup pump, operation of the primary pump, a water level warning, alow battery level warning, a battery fault warning, etc. In someexamples, the LEDs 512 can include a plurality of lights thatsequentially light up to indicate an amount of water or fluid in thesump pit. For example, the LEDs 512 can illuminate in a way to indicatea “low” “medium” and “high” water level so that a quick glance at thedisplay immediately indicates the amount of water in the sump pit (e.g.,fewer illuminated LEDs means low fluid level, intermediate number ofilluminated LEDs means higher fluid level, many illuminated LEDs meanshigh fluid level, all on and strobing to indicate too high of a fluidlevel or too high of a level for too long of a period of time, etc.).The notification module 510 can also be equipped with a speaker or otheraudible equipment to generate sounds or audible alarms in certainsituations. For example, the notification module can be configured tosound a buzzer or alarm when the water level is rising beyond apredetermined threshold or when the fluid level remains at or above athreshold level for too long a period of time, etc.

The communication module 520 can be configured to communicatenotifications via a number of wireless or wired technologies. Forexample, the communication module 520 can be configured to send textalerts via a cellular network. Additionally and/or alternatively, thecommunication module can be configured to send signals via a network,such as the internet, via a hard wired or a Wi-Fi connection, aland-line connection, or another approach. In this manner, thecommunication module 520 can communicate and/or interact with a remotedevice, such as a smart phone, a tablet, a laptop or other computer.

In some embodiments, the module 280 could allow battery back-up to powerthe communication module 520 and other modules or components (e.g., anelectronics module) during an AC power outage so that notifications, theapplication services described herein, and other features (e.g. cellularor digital notifications, such as text notifications, etc.) remainfunctional and/or operational.

FIG. 8 is a schematic diagram of an example control system 800 for anyof the tandem sump pump systems described herein. The control system 800(which can be the same as or similar to battery charging and controlsystem 300 described above with respect to FIG. 3) includes acontroller, such as microprocessor 810, in connection with a variety ofequipment, sensors, and outputs. The system 800 includes an AC pump 820represented by a motor symbol, which connects to an AC power supply 822(e.g., a 110 V AC power supply) and can be used to operate one pump of atandem sump pump system.

A current sensor 824 monitors the current drawn by the AC pump 820, andcommunicates with the microprocessor 810. In this manner, when currentdrawn by the pump 820 (e.g., by the pump motor) is above or below athreshold (e.g., signifying that the pump may be having issues), themicroprocessor can take any of a number of pre-prescribed actions. Forexample, detection of low current usage may indicate the pump has nomore water to remove and, thus, the controller may shut down the pump toavoid motor burnout. Detection of high current usage may indicate thepump is jammed and, thus, the controller may cycle the pump motor on andoff to try and dislodge whatever is causing the bind or may shutoff themotor and trigger a notification of an error. The microprocessor mayoperate any of the number of outputs, such as the audio alarm 870, LEDlights 880, or other functionality (such as sending a communication viathe communication module) to indicate or relay such errors.

In a preferred form, the system 800 will be configured with a firstswitch for operating the primary pump and a second switch for operatingthe backup pump. For example, switch 826 can be used to control thesupply of AC power to the system 800. In some examples, switch 826 caninclude any AC switch, such as a solid state relay (SSR) (e.g., anopto-triac or triac and alternistor, etc.). In the form illustrated, theswitch 826 is an opto-triac coupler, which can be employed to block highvoltage and voltage transients from the AC portion of the circuitry toother areas of the system 800, such as the DC portions of the circuitry.In this manner, the switch can help assure that a surge in the AC partof the system 800 will not disrupt or destroy the other parts of thesystem 800. In other examples, the switch 826 can include a DC switch ifthe circuit includes a transformer (e.g., an isolation transformer) andthe pump being operated is instead a DC pump.

Returning back to FIG. 8, the system 800 also includes a DC pump 830(again represented by a DC motor symbol) which can be used to operate asecond pump of the tandem pump system. The DC pump 830 receives DC powerfrom either a DC battery 834 (e.g., a 12 V battery), a battery charger832 (e.g., a 12 V battery charger), or a combination thereof. Forexample, the system may be setup to cycle usage of the pumps between thefirst and second pump 820, 830 so that one does not wear out before theother. Thus, when the DC pump 830 is to be used, the battery charger 832may simply be used as an AC-DC power adaptor to step the AC power supplydown to DC power to operate the DC pump 830 without requiring power tobe supplied by battery 834 so that the battery remains fully charged foruse during AC power outage situations. The battery charger 832 is incommunication with the AC power supply 822 and the battery 834, therebyensuring that the battery 834 maintains a charge in the event of an ACpower outage. The DC portion of the circuit also includes a currentsensor 838 that monitors current drawn by the DC pump 830, and a switch839 that opens and/or closes the DC portion of the circuit. In thismanner, the switch 839 can control the supply of DC power to the DC pump830 and the controller 800 can perform similar tasks to those discussedabove with respect to the AC motor when detecting too little or too muchcurrent draw (e.g., shut off the pump if too little current is drawnindicating insufficient fluid presence, cycle on and off the pump toattempt to dislodge a blockage leading to too much current being drawnby the motor, turning off the motor if too much current is drawn by theDC motor, etc.).

The system 800 also includes a voltage supply 836 that supplies powerfrom the DC battery 834 to the microprocessor 810 or as mentionedalternatively above from the battery charger 832 serving as an AC-DCadapter. With this configuration, the microprocessor 810 can stilloperate in the event of an AC power outage by drawing power from battery834. Another current sensor 842 monitors the current drawn by thebattery 834 to indicate to the controller 810 if a problem has occurredwith the battery 834 (e.g., too low or high of a current being provided,etc.). In other aspects current sensors can be associated with othercomponents of the system (e.g., the microprocessor 810) to monitor thecurrent that the components are drawing and further notifying of otherproblems or errors in circuit or component operation.

The system 800 includes a push-button 840, which can be pressed, forexample, by a user to activate one of a number of system tests. Forexample, the push-button 840 can be pressed to determine whether thebattery 834 is sufficiently charged. The push-button 840 can also beused for one or more other functions, including, for example, to silencean alarm, deactivate a notification, re-set warning signals, start atest cycle, or the like.

The microprocessor 810 also operates in connection with a number ofoutputs. For example, the microprocessor 810 may communicate data and/orinformation via a data output 850. The data output 850 can include, acommunication device that transmits text alerts, notifications, or othercommunications to a user via a remote device.

In some embodiments, the microprocessor may also include an auxiliarysignal output 860, which can be another auxiliary alarm, such as a homesecurity system and/or a communication/texting protocol system. Theauxiliary signal output 860 can include a switch 862 that allows theauxiliary output 860 to be activated or deactivated as appropriate.

The microprocessor 810 can communicate with an audio alarm 870 thatactivates an audio signal in response to certain events, or a series oflights 880 (e.g., LEDs) that can execute various lighting sequences inresponse to certain events as described herein.

In some embodiments the microprocessor 810 is also in communication witha number of additional switches and sensors, including, for example, afloat sensor 890, and a pressure sensor 895.

The system of FIG. 8 demonstrates various examples of redundancy and/orbackup to ensure proper operation of the system in the event of failureof some of the components. For example, the system 800 includesredundant pumps 820 and 830, redundant battery sensors 836 and 842 fordetermining battery performance, redundant power supplies 822, 834, andredundant water level sensors 895, 890. FIG. 8 does not provide examplesof controller and/or microprocessor redundancy. However, some examplesdescribed herein provide systems and/or methods to provide redundancyfor a controller such that the system can continue to function in theevent that the controller itself fails. This controller redundancy canbe provided in a variety of different levels, including a dual processorlevel that ensures full operation of many or even all of thefunctionality of the system even when a primary controller fails.Alternatively, simpler or less expensive systems can also be providedthat ensure operation of the pumps in the event of a controller failure,but without providing all of the other premium features of a moreexpensive dual processor system.

FIGS. 9-12 present examples of pumps and related systems that offerredundancy. For example, some systems include two pumps operated,managed, or otherwise controlled by a dual processor (e.g., a dualmicroprocessor). The dual processor can be configured so that oneportion of the processor operates a first pump (e.g., a primary pump oran A/C powered pump) while a second portion of the processor operates asecond pump (e.g., a backup pump or a D/C powered pump). In the eventthat one processor or processor portion goes down, the dual processorsystem can configure control so that the other operating processorassumes control of both pumps. In this manner, the system can continueto operate on all levels even in the event of a failure to oneprocessor. In some examples, the dual processor can be, or can includetwo separate processors, with each processor portion comprising aseparate processor device. In other examples, the dual processor is onechip or board configured to operate as a dual processor.

FIG. 9 is a schematic diagram of a redundant control system 900 for adual sump pump arrangement utilizing dual controllers, such asprocessors 910 and 911. In this embodiment, a first microprocessor 910can be configured to control operation of a first pump, for example, anAC powered pump 920. The second microprocessor 911 can be configured tocontrol a second pump, for example, a DC powered pump 930. Eachmicroprocessor can be in communication with various sensors, and otheraudio/video alarms or functionality. Moreover, in the event that onemicroprocessor fails, the other microprocessor can assume thefunctionality of the first microprocessor. For example, if the firstmicroprocessor 910 fails, the second microprocessor 911 can assumecontrol of the primary pump 920, while also assuming the control of thesignaling and other communication functionality described herein.Likewise, in the event that the second microprocessor 911 fails, thefirst microprocessor 910 can assume control of a backup sump pump 930,and other related functionality. Moreover, the system may utilizeredundant water level sensors, such as a pressure sensor 940 and a highwater float switch 942, each of which is in communication with each ofthe two microprocessors 910 and 911.

While utilizing a dual processor system such as that described withrespect to FIG. 9, such a system can be more complicated and expensive.Accordingly, the present disclosure also describes examples where oneprocessor is a simpler processor than the other. For example, oneprocessor may be a scaled down or scaled back version of the otherprocessor (e.g., a simplified controller) so that in the event of afailure, the simplified controller can perform some, but not all of thefunctionality of the primary processor. In this manner the system may bemore cost effective and easier to operate on account of the simplifiedcontroller, but may still be able to perform the important tasks (e.g.,prevent flooding) in the event of a primary processor failure so thatthe system can continue to operate in urgent situations. In some forms,the power supply for each of the controllers 910, 911 may be handledseparately as well in yet another example of redundancy. For example, aseparate transformer or step down/rectifier circuit may be used tosupply power to the first controller 910 and the battery may be used tosupply power to the second controller 911. In other forms, however, bothmay be powered from the same DC power source (e.g., such as the batterycharger as an AC-DC adapter and, if AC power is not available, from thebattery as discussed above).

FIG. 10 is a schematic of another example control system 1000 for atandem sump pump system with redundant controller features. The controlsystem 1000 includes a microprocessor 1010 in connection with a varietyof equipment, sensors, and outputs, including a primary pump 1020 (e.g.,an AC pump), and a secondary pump 1030 (e.g., a DC pump).

Unlike system 900 of FIG. 9 which includes dual controllers (e.g.,processors 910 and 911) that can maintain all or virtually all of thefunctionality of the system (e.g., including the warning, transmission,and monitoring features, etc.) in the event that one microprocessor orcontroller fails, the system of FIG. 10 operates on a more efficientbasis in the event that microprocessor 1010 fails. As such, the system1000 may be simpler and more cost effective, but still allow the pumps1020 and 1030 to continue to operate in the event of a failure while theprimary microprocessor 1010 or controller is being repaired or replaced.In this manner, the system 1010 may employ a redundant controller, suchas monitor 1001 that communicates, or is in communication with many ofthe system components. The monitor 1001 can be configured to essentiallymonitor microprocessor 1010 to ensure that it is operating effectively.When it detects that the microprocessor 1010 is not operatingeffectively, the monitor 1001 can assume control of one or both of theprimary pump 1020 and backup pump 1030 so that the essential pumpingoperations continue to operate as necessary.

In some examples, the monitor 1001 can serve as another microprocessorthat performs some of, but less than all of the functions of themicroprocessor 1010. For example, the monitor 1001 may be able tocontrol between operation of the two pumps 1020 and 1030, but notperform any of the alarm or communication functionality. In otheraspects, however, the monitor 1001 performs only a small number oftasks, sufficient to keep the system 1000 operating efficiently whilethe microprocessor 1010 undergoes maintenance. For example, the monitor1001 may be a simple logic circuit that includes a logic gate or logicgates (e.g., and/nand logic gates, or the like). Thus, the monitor 1001allows the system 1000 to operate minimally, such that only theessential operations are performed while the other module is replacedand/or repaired. This control system 1000 provides a less expensiveredundant system that allows the system to “limp home” in the event of afailure, thereby performing all necessary tasks.

In still further configurations, a very minimal redundant controller orsystem may be used that includes a simple relay switch without softwareor processors in the redundant/backup control. FIG. 11A is a schematicdrawing of a redundant control system 1100 for a dual sump pumparrangement utilizing a processor 1110 and a non-processor or logicbased relay controller 1111. The controller can be a simple switch or asimple relay, without any software or logic required to operate same(e.g., a software free controller). The microprocessor based controller1110 and the second or redundant controller 1111 can be provided in asingle enclosure as a control unit 1101 or, as will be discussed furtherbelow, be modular to allow for one to operate the system while the otheris serviced (e.g., repaired or replaced). In this manner, the simplerelay second controller 1111 can be wired to assume managementresponsibilities for the pumps 1130 and 1120 of the system in the eventthat the primary microprocessor controller 1110 fails or malfunctions.In this manner, the pumps will either operate (be “on”) or not (be“off”) as controlled by the relay controller 1111, which can be based onone or more sensors, such as float sensors and/or pressure sensors. In apreferred form, the redundant controller 1111 will be capable ofoperating both the primary and secondary pumps. However, in alternateforms, the redundant controller 1111 may only be capable of operatingone of the pumps (e.g., the secondary pump, but not the other).

FIG. 11B is a more detailed schematic of a redundant control system 1100a for a dual sump pump arrangement utilizing a processor and a dualswitch software-free relay controller. Here, the simple relay secondcontroller 1111 is shown in more detail as a dual redundant switchcontroller. That is, the second controller comprises a first redundantswitch 1111 a that operates the primary, or AC pump 1120, and a secondredundant switch 1111 b that operates the secondary, or DC pump 1130.The redundant switches for the controller system are two isolatedswitches with the outputs tied together and the inputs coming from twoindependent sources. Each switch 1111 a and 1111 b can take on a varietyof forms. For example, in some forms, similar switches may be used forboth the primary and backup pumps. In other forms, an AC switch mayutilize components capable of isolating the DC portion of the circuitfrom the AC portion of the circuit (e.g., an opto-triac switch), whilethe DC powered switch may include a simple mechanical switch, anelectrical switch such as a transistor (e.g., BJTs, FETs, etc.), or thelike.

For each switch 1111 a and 1111 b, the two inputs relate to themicroprocessor 1110 and the high water float switch 1190. If themicroprocessor 1110 fails to operate properly, the float switch, when itoperates, will turn on the switch output which will activate the ACswitch 1111 a (e.g., triac switch) or the DC switch 1111 b (e.g., FET)to drive one or both pumps 1120, 1130. FIG. 15 is a sketch showing asimplified circuitry for a switch 1111 c that could be used in such anembodiment. The switch 1511 includes a motor switch 1103 in circuit withtwo opto-isolators 1121 and 1122. However, it should be understood thatthe actual circuitry may be different for AC switch 1111 a and DC switch1111 b.

FIG. 12 is a schematic drawing of a system 1200 that allows two separatepumping systems 1220 and 1230 to communicate with one another. Forexample, in one form, the pump systems 1220 and 1230 may communicatewith one another when placed proximate each other via a communicationnetwork 1250, which can be a wired connection or a wireless connection(e.g., radio frequency (RF), infrared (IR), Bluetooth (BT), BluetoothLow Energy (BLE), near field communication (NFC), Wi-Fi, etc.). In theform illustrated, the systems 1220 and 1230 can communicate with oneanother and transmit operational status to a remote display unit 1240,such as a monitor or other display (e.g., a mobile phone, tablet, PDA,computer, or other network capable component).

The control unit 1201 can be configured to have multiple comminationmodes and/or communication circuits for transmitting notifications basedon the current availability of power and/or internet connectivity. Asshown in FIG. 34A, when the entire communication network 3400 is workingproperly, the control unit 1201 communicates via a wirelesscommunications circuit or module 1215 (e.g., a Wi-Fi module, Bluetoothmodule, RF module, etc.), which in turn communicates over the internetvia an Internet Service Provider (ISP) and a network connection devicesuch as a modem and/or router 1216 to send notifications to the remoteelectronic device (e.g., display unit 1240, such as a mobile device 1240a or personal computer 1240 b). The Wi-Fi communications module 1215 isa wireless communication circuit communicatively coupled to the controlunit 1201. In some forms, the Wi-Fi communication module communicateswith a local gateway, such as modem and/or router 1216 in order totransmit and receive information over the internet. However, ininstances of power failure it is not uncommon to also lose internetaccess along with line power/mains electricity.

Turning to FIG. 34B, the control unit 1201 modifies the communicationprocess or technique when internet access is lost. More particularly,when the Wi-Fi communications circuit or module 1215 loses contact withthe modem and/or router 1216 a notification is sent to the Wi-Ficommunications circuit or module 1215 and/or control unit 1201. In someforms, the notification comprises a cessation in responses received atthe control unit 1201 or Wi-Fi communications circuit or module 1215from the internet service provider or modem and/or router 1216 or theremote display unit 1240. When this lack of internet connection isdetected, the Wi-Fi communications circuit or module establishes directcommunication with the mobile device 1240 a by broadcasting in a Soft APmode. The direct communication is short range, communicating with themobile device 1240 a only if it is onsite and within range of thebroadcasted Soft AP signal. The range is limited by the range of theWi-Fi communications circuit or module 1215, such as the range of astandard Wi-Fi connection (e.g., 0-200 feet and in a preferred form upto 100 or 150 feet). In alternative forms, other protocols are used,such as Bluetooth, Bluetooth Low Energy, Near Field Communication, RadioFrequency, Infrared, or Zigbee. In order to work during power failures,the Wi-Fi communications circuit or module 1215 is powered by thebattery backup discussed herein. In this way, the system is capable ofcommunicating during normal operating conditions via a primarycommunication means (e.g., a primary wireless communication circuit) andvia a secondary communication means (e.g., a secondary wirelesscommunication circuit) when the primary communication means isunavailable.

The pump system 1200 includes an actuator, such as button 1214, forestablishing the direct wireless communication mode (e.g., to put thesystem in broadcast Soft AP mode or direct connection mode). In the formillustrated in FIGS. 34A-B, the button 1214 is located on the pumpsystem 1200, and specifically on pump 1201 itself, however, in apreferred form, the button 1214 will be located outside of the sump pit403 such that it can be more easily accessed (e.g., such as on thecommunication module 1215 in FIGS. 34A-B and 37A-B, or 520 in FIGS.5A-B; on the remote display 2800 in FIGS. 28 and 37A; on the controller1201 in FIGS. 37A-B, 2900 in FIGS. 29A-B, 3120 in FIG. 31, or 3201 inFIGS. 32A-B; and/or on the integrated controller and remote display 300in FIG. 3, 441 in FIG. 4A-B, 520 in FIGS. 5A-B). Pressing the button1214 allows the system to broadcast in Soft AP mode so as to create ahotspot that remote devices can pair to in order to continue to get pumpdata from the system even though the primary wireless network connectionhas gone down for some reason. In some forms, pressing the button onlycreates a temporary pairing, such that it needs to be paired again whenthe primary wireless network connection goes down or future servicevisits.

While such a button or actuator is provided for configuring the systemin or putting the system into the broadcasting Soft AP mode or directconnection mode, in a preferred embodiment the system will be configuredto automatically start in the Soft AP mode when initially powered up sothat a technician or installer can install the pump and confirm it isoperating via a downloadable software app without the need to obtain anetwork password from the home or business owner having the pumpinstalled. This allows the owner to keep his/her/its network passwordsecret and, thus, does not require the owner share the password withothers and then reset the network password later to ensure networksecurity. Thus, the direct connection or Soft AP mode is useful for bothsetup & install of the system, and for allowing the system to continueto communicate data about the system with a remote device while theprimary wireless communication network is down. In some examples, thedirect wireless connection is also used during maintenance and serviceof the system. A technician can directly communicate with the controlunit 1201 without needing the SSID and password for the primary wirelesscommunication mode. This prevents the owners of the pump 1200 fromneeding to give their secure SSID and password to a technician, and indoing so reducing their security.

FIG. 35A is a flow chart illustrating an exemplarysetup/install/maintenance process for the pump system 1200. First, instep 3502, the person installing the system, such as a technician,downloads the mobile application to their electronic device, such as asmartphone. In a preferred form, the application may be used for aplurality of pump systems 1200, so a technician will only have todownload the application once and then can use it during eachinstallation job. Thus, if the app has already been installed, thetechnician/user can proceed to the next step. The app will preferably beavailable at one or more major app stores or marketplaces, such as theapp stores for iOS and Android OS platforms (e.g., Apple App Store,Google Play Store, etc.).

Next, in step 3504, the technician installs the pump system 1200. In apreferred form, the pump system 1200 includes a display device, such asthe remote display panel 2800 illustrated in FIG. 37A, in addition tothe Wi-Fi communications module 1215. Both the display panel 2800 andWi-Fi communications module 1215 are installed higher than the pumps1220 and 1230 so that they can be more easily accessed and/or viewed byusers, such as the owner or resident of the premises the pump system1200 is installed in. FIG. 37A illustrates the pump system 1200 with thedisplay panel 2800 and Wi-Fi communications module 1215 at a raisedposition, even above system controller 1201.

After powering on the device in step 3506, the system is thenautomatically started in the broadcast soft access point (Soft AP) modeto serve as a hotspot that the technician can connect his/her remotedevice to in order to finish installation. If for some reason the systemdoes not start-up in Soft AP mode or if an error has occurred during theinstallation process, the technician can put the system into the Soft APmode by pressing the button 1214 on the Wi-Fi communications module 1215or by selecting the “installer portal” link on the app as illustrated inthe app screen display of FIG. 36A and then following the necessarysteps to place the Wi-Fi communications module 1215 in to its directcommunication or Soft AP broadcast mode (note: these steps are discussedfurther below). Alternatively, the technician can actuate the “Reset”button 1217 on the Wi-Fi communication circuit or module 1215 as shownin FIG. 37B to return the Wi-Fi communications circuit or module 1215 toits initial factory settings and try restarting same. FIG. 37B is anexpanded view of the Wi-Fi communications circuit or module 1215 showingthe direct communication/Soft AP button 1214, the reset button 1217, andone or more status lights 1218. In a preferred form, depressing thedirect communication/Soft AP button (referred to as the LOCAL LINK™button in FIG. 37B) for a period of five seconds (5 s) causes the Wi-Ficommunications module 1215 to broadcast under Soft AP mode and act as ahot spot, such that other Wi-Fi devices, such as the technician'ssmartphone or tablet, can form a direct wireless connection therewith.In a preferred form, however, other conditions will also need to be metwithin the device firmware in order for the system to convert to thedirect communication/Soft AP mode (e.g., the Wi-Fi connection mustalready be down before the system will change to direct communicationsmode).

As mentioned above, in some forms of the invention the technician canselect the “Installer Portal” link illustrated in the screen display ofFIG. 36A and in step 3508 to place the system in broadcasting mode andthen select “OK” in the pop-up box of the screen display illustrated inFIG. 36B once the pump hotspot has been selected from the list ofavailable Wi-Fi networks on the device the technician is using (step3510). However, in a preferred form, the system is setup such that thedirect communication/Soft AP button 1214 must be pressed to get theWi-Fi communication circuit or module 1215 into directcommunication/Soft AP mode, and in some forms the button must bedepressed for a plurality of seconds to ensure it was an intentionalactivation (e.g., 5 s). In a preferred form, the pump hotspot isillustrated with the name WW-GEM100000XX with the latter digits beingthe Wi-Fi communication circuit or module serial number (however othernumbering schemes could be used, such as the pump serial number, etc.).In the exemplary screen display of FIG. 36C, the pump hotspot isillustrated as WW-GEM-10000009 which relates to the Wi-Fi communicationcircuit or module serial number. Once the installer selects the pumphotspot from his/her available Wi-Fi networks, the app should illustratea scrollable screen like that illustrated in FIGS. 36D-F which displaysinformation about the current pump system state. This allows theinstaller or technician to check the status of the pump system asillustrated in step 3512 of FIG. 35A and if successful (step 3514), thetechnician portion of the installation is complete and the techniciancan instruct the owner how to finish setup/registration as indicated instep 3518. If any of the tiles of the app indicate something is wrongwith one of the system components such as the battery is dead, one ofthe pumps is offline, etc., the technician can continue troubleshootingthese items until all items are fixed before departing. If the screendisplay is not displayed successfully as checked in step 3514 (e.g., theapp does not load, etc.), the technician can reset the system byactuating actuator 1217 (see FIG. 37B) to reset the system as called forin step 3516 and restart the Soft AP process as indicated in step 3508.By going through the direct connection and the installer portal, thetechnician does not need to acquire the account and password informationor the password for the owner's Wi-Fi network.

As indicated in FIGS. 36D-F, the dashboard illustrated as the scrollablescreen display of FIGS. 36D-F is comprised of a compilation of “tiles”or boxes that each relate to a different system component or functionand provide a status or attribute relating to same. Thus, as illustratedin FIG. 36D, the top left tile is entitled “AC Power” and in green theapp identifies that AC power is “ON” within the tile. Similarly, underthe second tile entitled “Battery Health” the system indicates batteryhealth is “GOOD”. The third tile entitled “Hours of Protection” providesa battery symbol colored in green to indicate how well the battery ischarged and estimates how long it will last for if called into action.In a preferred form, the battery symbol and text will indicate acombination of the data from the remote display unit 2800 illustrated inFIG. 28 which indicates if four possible states (e.g., battery healthis: good, ok, poor or needs to be replaced; and hours of protection is:greater than 4 hours, 2-4 hours, 1-2 hours or greater than 1 only). Thebattery image will show varying states of fill and can change from greento other colors reflective of the charge (e.g., green for good charge,yellow for ok charge, and red for poor and replace. In other forms, thebattery may remain green, but show varying stages of filled in greenarea to indicate battery charge (e.g., all green for fully charged,three quarters green for ok charge, two quarters green for poor and onequarter green for needs replace or recharge). The lightning bolt imageor symbol shown in the battery of FIG. 36D indicates that the battery ischarger. In a preferred form, the system will use a 75 amp-hour absorbedglass mat (AGM) battery, but can also use deep cycle batteries ifpreferred (e.g., deep cycle marine battery, etc.). The battery case thatthe battery is kept in can be designed for varying sizes of battery, butpreferably will fit up to a 31-frame size battery.

In a preferred form, the scrollable screen display of FIGS. 36D-F willalso have additional tiles indicating if the AC primary pump is ready,if the DC pump is ready and what the current water level is in the sump.In the form shown, the app is also configured to provide buttons forrequesting to “RUN SYSTEM TEST” and/or “MUTE ALARM”. If a run systemtest is selected, the system will run the primary pump for apredetermined period of time (e.g., seven seconds (7 s)), and then,after a short pause, run the back-up for a predetermined period of time(e.g., seven seconds (7 s)). In some forms, the run system test may alsobe configured such that the system will check the battery to determineits state of health (SOH), however, a preferred form of the system willrun this SOH test on a monthly basis unless initiated manually. Anaccurate assessment of the battery SOH requires several days for thebattery voltage to stabilize. As the battery ages, the SOH will slowlydecline and eventually a “replace battery” indicator will illuminateindicating the battery's ability to hold a charge is severelycompromised. If the mute alarm actuator is actuated, the audible alarmwill be muted for a predetermined period of time. In a preferred form,the owner can press the mute button once to mute the alarm for one hour,twice to mute the system for two hours, three times to mute the systemfor three hours and so on up to eight button pushes/eight hours. Thesystem test and mute can be accomplished by selecting these buttonseither on the app (see FIG. 36F) or on the remote display (see FIG. 28).

In the form illustrated, the system will remain in Soft AP mode untilchanged over to its primary wireless communication mode, however, inalternate forms the system may be configured to time out of Soft AP modeif an available wireless network connection is detected or even withoutif desired. In one form, the Wi-Fi communication module 1215 includes atimer and stops acting like a hot spot after a predetermined amount oftime. In some forms, the predetermined amount of time is an amount oftime in hot spot mode with no external electronic device connected. Oncethe hot spot mode is terminated, the Wi-Fi communication module 1215attempts to re-establish connection to any stored networks, such as tothe local wireless router.

FIG. 35B illustrates an exemplary flow chart process 3550 by which thehomeowner or resident finishes installation of the pump system and/oruses the pump system 1200 after installation. As in the process 3500,first the homeowner installs the software application on a desiredelectronic device in step 3552. It should be understood, however, that atechnician, homeowner or other user of the system could setup the systemand use same by accessing a website portal as well in case they do nothave a smart phone or wish to use an App version of the system. Forsimplicity sake, this disclosure assumes the App will be used and, thus,describes setup and use of the system using the App example. When theapplication is opened a sign-in screen is displayed, see FIG. 36G. Ifthe homeowner already has an account and password, it can be entered onthis screen using the input device of the owner's electronic device,such as the touch screen on a smartphone or tablet. If not, the userselects sign-up on the screen of FIG. 36G to access the sign-up page ofFIG. 36H and create an account and register the pump system. Once anaccount is created, the user will only be required to visit the sign-inpage of FIG. 36G and no longer will need to visit the sign-up page ofFIG. 36H unless desired.

At the sign-up/registration page of FIG. 36H, the homeowner registers anaccount in step 3554 by entering information into the displayed form,see FIG. 36H. After registering an account, the user establish awireless communication for the pump by selecting the preferred wirelessnetwork and entering any necessary password for same in step 3556. Aftera wireless network is established, the owner will see the scrollable appscreen display of FIGS. 36I-K which provides information similar to thatdiscussed above with respect to screen display FIGS. 36D-F to checkprovided status of pump systems in step 3558. If not already apparent,FIGS. 36I-K are meant to collectively display all the content on thescrollable screen display and thus illustrate overlapping repetitiveportions of the screen display (this is true for FIGS. 36D-F as well).In some forms, the homeowner's initial setup will use the directconnection technique mentioned above until the wireless password orother required information is entered. Once entered, however, the systemwill communicate via the primary wireless connection and only use thedirect connection communication (or the secondary wireless communicationmethod) if the primary wireless communication method is not available.

If the primary wireless communication connection is lost (as is checkedin step 3560), the application displays the fault screen, see FIG. 36M.The fault screen notifies the user that the pump system 1200 is offline,and provides a link to establish a secondary wireless communicationmethod, e.g., the direct connection or Soft AP connection discussedabove (see the link entitled LOCAL LINK™ in offline banner on upperright of screen display in FIG. 36L). When this occurs, the status boxeson the screen or tiles are faded or greyed out to convey to the viewerthat they are not being updated and reflect the last known data for eachfield/tile prior to the primary communication network becomingunavailable.

As with the technician installation discussion above, the pump ownerwill be prompted to establish a direct connection via the secondarywireless communication method (e.g., the direct connection or Soft APmode) beginning with the pop-up window of FIG. 36M in step 3562. Onceselected, the user is prompted in step 3564 to hold the directconnection button 1214 (see FIG. 37B) in for five seconds (5 s) (oractuate it for 5 s) to place the pump communication module in the SoftAP broadcasting mode to establish a direct connection with the owner'selectronic device. Once done, the owner must select the pump systemhotspot from the list of available wireless networks displayed on theuser's electronic device as illustrated in FIG. 36O and indicated instep 3566 and then select “OK” in FIG. 36N. Again, in the formillustrated, the pump system hotspot is identified as WW-GEM-10000009.Once selected, the owner will see pump system status data similar towhat is shown in FIGS. 36D-F and as specified in step 3568. If theprimary wireless network is not available due to a power outage (meaningloss of line power or mains power), the initial screen may be modifiedto list the AC Pump tile as “OFF” and list the AC Primary Pump tile as“OFFLINE” due to no line power being available as illustrated in screendisplay or shot FIG. 36Q. In the exemplary embodiment of FIG. 36Q, thebattery health and hours of protection tiles have also been altered toshow what the app may display (at any time) if the battery health ispoor or if the battery has only one hour or slightly more of batterylife left just to give an exemplary illustration of same. In a preferredform, these battery life and hours of protection tiles will be the sameas those shown in FIG. 36I meaning that the battery is fully charged andin good health even if the AC pump is OFF/OFFLINE.

If the primary wireless communication network becomes available againwhile the direct connection is established (as is checked in step 3570of FIG. 35B), the system prompts the user by asking if he/she wishes toterminate the direct connection and go back to the primary wirelessconnection as illustrated in step 3572 and FIG. 36P. If the user selectsleave the direct connection (called LOCAL LINK™ in FIG. 36P), the systemwill drop the direct connection and reconnect to the primary wirelessnetwork connection and begin checking the status of the pump system asdone in step 3558 of FIG. 35B. If the user elects to stay connectedunder the secondary communication connection (i.e., the directconnection), the system will continue to check the status of the pumpsystem as done in step 3568. In the form illustrated, the systemrefreshes its status data much quicker under the primary communicationconnection than it does under the secondary communication connection(e.g., primary communication connection refreshes almost instantaneously(microseconds or milliseconds) versus the secondary communicationconnections much slower refresh rate of three or more seconds). Inaddition, in some systems, the user may not be able to utilize his/herelectronic device for other uses while it is under the secondarycommunication connection (e.g., the user will not be able to utilizeother available wireless networks such as other Wi-Fi networks, 4G orLTE or may have limited usage of other networks or features on theuser's electronic device such as limits on broadband cellular networksand data or apps that would otherwise be usable on the user's device).Thus, it is contemplated that most users will opt out of the secondarycommunication connection/direct connection in favor of the primarycommunication connection. As mentioned above, the system may also beconfigured to connect the user out of the direct connection or secondarycommunication connection after a predetermined period of time has beendetected. In yet other embodiments, the system may be configured to dothis automatically without prompting the user in the manner shown inFIG. 36P and step 3572 if desired.

The system 1200 can include a control unit 1201, which can be providedas a part of the system 1200, or as an independent, or replaceablecomponent. The control unit 1201 can include a backup battery 1234, andtwo control modules 1210 and 1211. Alternatively, the two controlmodules 1210 and 1211 can be independent components that are installableseparately with respect to respective pump systems 1220 and 1230. Eachpump system 1220 and 1230 can include an AC pump or a DC pump, each ofwhich can be associated with a sensor such as an air tube/pressuresensor 1224 or a float switch 1235. Each control module 1210 and 1211can be used to operate the corresponding pumping system, while in turncommunicating via network 1250 with the other module. The remote displayunit 1240 can display the results of the communications between the twosystems. For instance, the remote display unit 1240 may communicate viaBluetooth, 4 wire, other radio frequency transmission or another similartechnique with the control unit 1201. In this manner, the two systemscan be configured to operate in tandem, though the systems may haveoriginally been provided or purchased independently. For example, withthis configuration, the primary or secondary pump may be able to takeover the operational tasks of the other pump and, in a preferred form,even operate the other pump such as when a controller on one pump goesbad or fails. Ideally, in such a failed controller situation, thecontroller that assumes operational control of the system will be ableto operate both pumps so that the pumps may be cycled on alternately (oralternately activated) to prevent one pump from dying before the otherdue to excessive use as compared to the other. Another benefit of havingthe controllers set up in this manner is to allow the controller thathas assumed operational control to activate both pumps simultaneously orat least together at some point should fluid be rising at a rate thatrequires both pumps to operate in order to keep up with the rate thefluid is rising.

Thus, in summary a pump system is provided which communicates via aprimary pump communication circuit or network during regular operationand via a secondary pump communication circuit or network when theprimary pump communication circuit or network is unavailable. In someforms, the primary communication circuit or network is a wirelessnetwork and the secondary pump communication circuit or network is adirect communication network. For example, in a preferred form, theprimary communication circuit or network is a Wi-Fi local area networkand the secondary pump communication circuit or network is a directcommunication network using Soft AP, Bluetooth, Bluetooth Low Energy,Near Field Communication, Infrared or Zigbee communication protocols.

A battery back-up pump system is also contemplated herein utilizing theabove mentioned pump system. In one form, the battery back-up pumpsystem includes an AC pump, a DC pump, a controller having a primarywireless communication circuit and a secondary wireless communicationcircuit. The primary wireless communication circuit preferablycommunicates via a Wi-Fi local area network and the secondary wirelesscommunication circuit communicates via a direct connection with a pairedremote electronic device when the Wi-Fi local area network isunavailable.

A benefit to having redundant systems as discussed in the embodimentsabove, is the ability to prevent flooding due to a system or componentfailure and to give a pump owner peace of mind as to the operation ofhis/her pump even when network and/or power outages occur. However, asmentioned herein, another benefit to such redundancy is the ability toservice one pump while allowing the other pump to continue to operate.Furthermore, as mentioned above, an advantage to having a redundantcontroller configuration is the ability to continue to offer pumpingcapabilities when failures occur. As also mentioned, it is desirable toconfigure the system so that a failed component (e.g., pump, controller,etc.) can be removed while the other component or remaining componentscontinue to operate or offer pumping capabilities. As such, in apreferred form, the controllers may be configured so that separatecircuits or circuit modules are utilized to allow a controller to beremoved and serviced or replaced while the other controller remains inplace and operational. Similarly, it is desirable to have all othermodules of the system to offer redundancy and serviceability withoutdisrupting at least partial operation of the system. Some preferredsystems in accordance with this disclosure will also notify a user ofany system or component failure or malfunction so that the systems orcomponents may be serviced timely.

The present disclosure presents examples of a sump pump system thatincludes a primary sump pump, which can have an AC power supply, abackup sump pump having a DC power supply, and a controller. Thecontroller can be in electrical communication with the primary sump pumpand the backup sump pump, the controller configured to communicatewirelessly with at least one remote device.

In some examples, the controller can be configured to control othersystems as a central control module (e.g., sewage or utility pumps ordrainage pumps located elsewhere such as outside of home/building).

In some examples, the controller can be configured to communicate withother equipment in a home, such as HVAC equipment, telephone orcommunication equipment, refrigerators, freezers, ice makers washers,dryers, dishwashers, or other appliances, water meters, home securitysystems, or the like.

The controller can supply output signals to support multiplenotification technologies (analog, cellular, digital, other). The systemcould be configured to send one-way “push” notifications only or,alternatively, provide two-way communication (e.g., remote actuation ofpump, diagnostic check, etc.).

The control components of the system, such as system 300 of FIG. 3, canbe configured in a variety of ways. For example, they can be combinedwith the battery charging electronics and mounted in a highly visiblelocation in the surrounding area of the unit (e.g., on the basement wallfor a sump pit, or on the discharge pipe near the sump pit, etc.). Insome examples, the system 300 can also include a 12 V DC output 370and/or an AC output 380. These outputs 370, 380 can be used to providepower to other ancillary devices or equipment, such as communicationdevices, signaling equipment, sensors, test equipment, light sources,etc.

The sump control system enclosure can also accommodate the batterycharging electronics, thereby moving the charging components away fromthe harsh environment of the battery box and into an area moreconvenient for viewing & operation by the home owner (ref. sealed sumpunits with Radon sensors).

In some examples, the system includes a pressure switch that, along withthe controller, can also operate both the first and second (e.g., AC andDC) pumps, thereby alleviating the use of multiple float-type switchesin the sump pit so that the system is more compact and fits into smallerdiameter pits found in many older homes.

In the event of high water intake, the central controller can operateboth AC & DC (or two A/C) pumps simultaneously to remove a higher volumeof water from the basement. The central controller could also alternateactivation between pumps to effectively “exercise” each system to ensureoperation and to balance the number of cycles on each unit.

The central control system can supply output signals to support multiplenotification technologies (analog, cellular, digital, other). The systemcould be configured to send one-way “push” notifications only or,alternatively, provide two-way communication (e.g., remote actuation ofpump, diagnostic check, etc.).

The controller can include a communication module and is thus configuredto communicate wirelessly via a network. For example, the controller canbe configured to communicate via a Wi-Fi signal or via a cellularnetwork. In some examples, the controller can also monitor variousevents relating to the operation of the sump pump system. For example,the controller can be configured to monitor the operating status of theAC power supply, the power level of the DC power supply, the operatingstate of the primary and/or backup sump pump, problems during operationof the pump, a cycle count of the primary and/or backup pump; anelectric current draw rate of the sump pump system, a water level at oraround the sump pump, and the rate at which the water level is rising orfalling in the sump.

The controller may be configured to perform diagnostic operations on atleast one of the primary sump pump and the backup sump pump. Thecontroller can also be configured in some examples to monitor andcommunicate in real-time information relating to the fluid level, thebattery state, the current usage, and the on/off status of the equipmentof the sump pump system. In some approaches, the controller includes acommunication module, is configured to communicate notifications to aremote device, such as a smart phone, a tablet computer, or anthercomputing device. The communications module could be a separate unit orintegrated into the control enclosures. The controller can be configuredto communicate notifications at predetermined time intervals, or duringpredetermined time periods.

The controller can be configured to automatically communicatenotifications in response to the detection of certain events. Forexample, the controller may be configured to communicate notificationsrelaying information pertaining to a power outage, a change in theoperation state of the primary and/or backup sump pump (e.g., the backuppump turns on, off, or increases/decreases in pumping rate, frequency ofoperation, cycles, etc.), the detection of a battery level of the DCpower supply below a predetermined threshold (e.g., the battery has lessthan 50%, 25%, 15%, 10%, or 5% power, etc.), a detected problem in theoperation of the pump, a detected cycle count of the primary and/orbackup pump exceeding a predetermined threshold (e.g., the pump hasperformed about 50% of the life expectancy of the pump), an electriccurrent draw rate of the primary and/or or backup sump pump above apredetermined threshold, a detected water level rising above and/orfalling below a predetermined threshold, and a detected water levelrising and/or falling at a rate above and/or below a predeterminedthreshold (e.g., water is rising faster than the pumping system canpump). In some aspects, the controller is also configured to monitor andreport on the brush life of the DC pump motor (or any pump motor) bydetermining the total “on” time (i.e., the total time in which the pumphas been running) throughout the life of the pump. Thus, once the motorhas been operated or cycled on for a predetermined amount of timeassociated with a certain percentage of motor brush wear, the systemwill provide a notice (e.g., audible and/or visual alarm, datanotification such as text or alert, audible communication, etc.). Thispredetermined amount of wear can be any amount desired, (such as 75%wear, 80% wear, 90% wear, 95% wear, 100% wear, etc.), and may includemultiple notices to increase the likelihood that the motor will betimely serviced before a failure occurs (e.g., such as by replacing themotor brushes before they reach or by the time they reach what ispredicted to be 100% wear).

Some versions of the controller are configured to communicatenotifications that offer coupons for new system in response to thecontroller detecting a life cycle count has exceeded a predeterminedthreshold. For example, when the controller detects that the pump hasreached the midway point of the life expectancy of the pump (or its lifeexpectancy), the controller may send coupons, reminders, or othernotifications to alert a consumer to purchase a new pump and/or performservice or maintenance on the pump. In some aspects, the controller maycommunicate notifications that offer an extended warranty option forsystems that the controller has detected a life cycle count that exceedsa predetermined threshold (e.g., indicating that the user may want topay for such extended coverage given its system is detected to beworking at usage levels that exceed normal usage guidelines orthresholds). In some approaches, the controller is configured to trackunit parameters that provide insight into whether a warranty should behonored. For example, the controller can track whether warningnotifications have been properly addressed and/or ignored by the pumpowner. That is, the controller may determine that a sump pump systemfailure is a result of ignored notifications communicated by thecontroller, and use this information to determine if warranty status isstill authorized.

In some forms, the controller can receive communication signals from aremote device, and perform functionality in response to thecommunication signals received from the remote device. For example, thecontroller can be configured to receive signals from a user operating anapplication on a remote device (e.g., a smart phone) that instruct thepump to turn on, turn off, activate a backup pump, etc. In response thecontroller will effect operations of the pump accordingly (e.g.,self-test, self-diagnostics checks, etc.).

Some examples described herein also present a mobile application used inconnection with a sump pump system. The application can be configured tooperate on a remote device, such as a smart phone, a tablet computer, orthe like (“app”). The mobile “app” may include an interface that canprovide information to the user, and can allow the user to executevarious functionality.

In some approaches, the app is configured to operate one or more of avariety of features. For example, the application can be configured tooperate one or more of the following features/functions:

-   -   (1) display key system status parameters (water level, battery        state, power on/off);    -   (2) perform diagnostic check/systems test;    -   (3) provide real-time fluid level feedback, battery state,        current usage, on/off state, etc.; (the app can provide active        feedback or a closed-loop controller concept);    -   (4) track real-time or time lapsed pump usage and prompts        notifications at desired time periods;    -   (5) offer coupon for new system once predetermined life cycle        count has been reached;    -   (6) offers extended warranty option when pump is approaching        original warranty limit; and/or    -   (7) tracks unit parameters to provide insight on whether        warranty should be honored or not (e.g., if system repeatedly        advised user of problems and failure was due to user ignoring        notifications).        It should be understood that reference to “real-time” as used        herein may mean exactly that, i.e., real-time data, or it may        include slightly time-delayed data that may be better described        as nearly real-time or not old/historical data.

The system can be configured to execute/display/operate the samefunctions on a display associated with the unit itself (e.g., a displayinterface at or around the controller or integrated module) that areexecuted on the app. Some examples described herein also apply the useof a pneumatic pressure switch that eliminates and/or reduces the numberof moving parts, which can result in an increase in system reliability.FIGS. 4A-B are sketches showing an example system 401 that uses apneumatic pressure switch. The system 401 includes a sump pump 400 and apressure tube 440 in a sump pit 403. The sump pump 400 is connected to apower source 410 (e.g., a 120 V AV 60 Hz outlet) via a sump pump powercord 404, and is configured to pump fluid out of the sump pit 403through the pump discharge outlet 460. The pressure tube 440 has apressure tube inlet 447, and is connected to a switch device 441 via aflexible tubing 442. The switch device 441 can be or can include apressure transducer, a printed circuit board, a microprocessor, a triacswitch, or the like. A piggyback cord 445 supplies electrical power tothe switch 441 from the power source 410. The pneumatic pressure switchsystem 401 of FIGS. 4A and B can be configured to flush air after apredetermined period to recalibrate and eliminate problems withcondensation build-up or tube leakage. In some examples, the pneumaticswitch tube 440 could be of a basic plastic construction, or wholly orpartially constructed from copper to help reduce the build-up of ironochre. While it is known to use capacitive sensors in sump pump systems(see, e.g., U.S. Pat. No. 8,380,355, and U.S. application Ser. No.13/768,899 (Mayleben et. al.), owned by Wayne/Scott Fetzer Company, bothof which are hereby incorporated by reference in its entirety), suchsystems may evoke additional steps to ensure that the air tube is backto atmospheric pressure. The present disclosure describes systems thatemploy sensors that are adapted to operate so that the water level isheld below an opening. In this manner the fluid level in the pitmaintains a certain level with respect to the fluid level in the tube(e.g., the pit and tube fluid levels do not have to be equal or levelwith one another, but rather simply correlate with one another so thatthe level in the tube can be used to calculate a corresponding level offluid within the pit). Further, in some examples, the systems will beconfigured to turn on after a predetermined time so that the air in thetube returns to atmospheric pressure.

Some examples described herein provide a variety of uses andfunctionality. One embodiment includes a pump volute design thatsupports close nesting of pumps. Another embodiment includes a waterlevel sensing algorithm that receives inputs from an air tube to a PCBmounted pressure transducer. Though the air tube can be arranged in avariety of configurations, in some aspects the air tube may be arrangedin a generally vertical orientation. Another embodiment includes theability to remotely mount the sensing/switching electronics out of thesump pit. Some examples described herein provide an integrated waterlevel sensing & DC battery charger electronics in one enclosure. Someaspects described herein provide a communications module that canreceive & send data from the central control unit. Some examples includea mobile application that can receive push notifications showing systemstatus. Still other examples, offer two-way data communications betweenApp & central control to allow remote system test.

Some examples described herein present a redundant control system for apumping system or pumping arrangement. The pumping arrangement has atleast one pump, and can include a primary (e.g., an AC) pump and asecondary or backup pump (e.g., an AC backup pump or a DC pump). Theredundant control system includes a primary controller that directs ormanages operation of the at least one pump, and a secondary controllerthat controls operation of the at least one pump in the event that theprimary controller is inoperable, unavailable, or otherwisenon-functional. In some forms the primary controller controls operationof the primary pump and the secondary controller controls operation ofthe secondary or backup pump. In some examples, the secondary controlleris configured to control operation of the first pump in the event thatthe primary controller is inoperable.

The controllers can be either AC powered, DC powered, or both. Forexample, the primary controller may be an AC powered controller and thesecondary controller can be a DC powered controller, but also beprovided with an AC supply that keeps the DC powered controller charged.The controllers can take on a variety of forms. For example, in oneaspect, the primary controller may include or be a primarymicroprocessor. The secondary controller can also be a softwareexecuting apparatus, such as another microprocessor, a logic circuit, orthe like. In certain embodiments the secondary controller can performall of the functionality of the primary microprocessor. However, inother embodiments, the secondary controller is limited in functionality,and can only perform some of the duties of the primary controller. Forexample, the secondary controller may only be able to turn on and offthe pumps of the pumping arrangement. In some aspects, the secondarycontroller is software-free utilizing a relay or a mechanical switch. Insome aspects, the secondary controller includes a monitor configured toobserve operation of the primary controller, and can assume operation ofboth the primary and secondary pumps, if required.

It should be understood that the presently described pumps, systems,controllers, and related equipment can be utilized in a variety ofdifferent methods or processes. That is, the present disclosurecontemplates using the described pumps, systems, equipment, or the likein a variety of methods, processes, or techniques that utilize theadvantages of the related equipment. For example, one method involvesreducing the footprint (e.g., reducing the overall occupied space) of atwo-pump pumping system. The method includes connecting a primary pumpcheck valve and a secondary pump check valve to discharge outlet with across-over pipe that extends over the primary pump and the secondarypump, placing the two-pump pumping system into a sump pit, andconnecting the discharge outlet to create a redundant system.

Another method involves activating a pump of a sump pump system. Themethod includes providing a primary controller electrically connected toa primary pump, whereby the primary controller has a primary interfacefor communicating with a primary and secondary pump. The primaryinterface is operated to activate the primary pump, a secondary pump, orboth pumps, when the fluid level sensor indicates a predetermined fluidlevel has been reached.

Another method involves placing a two-pump pumping system into a sumppit. The two-pump pumping system includes a first pump having a firstvolute and a first discharge pipe segment, and also includes a secondpump having a second volute and a second discharge pipe segment. Thefirst and second discharge pipes are connected to one another tointerconnect the first and second pumps to one another. The two-pumppumping system can then be placed into a sump pit as an integratedassembly. In such configurations, a check valve would be positioned inline with each pump discharge or in other forms an isolation valve likethe one discussed further below could be used.

Yet another method involves pumping fluid from a sump pit with atwo-pump pumping system. The method includes pumping fluid from the sumppit with the primary sump pump, and detecting one or more conditionsassociated with at the pumps and/or the sump pit (e.g., the fluid levelin the sump pit). In response to detecting one or more predeterminedconditions, the secondary pump is then activated to pump fluid from thesump pump. For example, when the method detects that water in the sumppit has exceeded a predetermined height, the secondary pump can activateto facilitate the pumping of the primary pump.

Other methods relate to the transmission of notifications that relate toa pumping system installed in a sump pit. First, one or more pumpingconditions associated with at least the pumps or the sump pit aredetected via one or more sensors. In response to detecting one or moreconditions (which may be predetermined), a controller will transmit asignal, for example, to a remote device. The signal can includeinformation or otherwise notify a user of the circumstances associatedwith the detected conditions.

As discussed above, some examples of the dual pumping system includedual pumps that are integrated via a shared volute or other structuraldesigns that combine the volutes of two pumps into a common space. Thesepump volutes can be manufactured together as a single component, or theycan be joined via components that inhibit separation of the two pumps.For example, the pumps may be cuffed or otherwise connected via abracket or other structure.

FIG. 16A shows an exemplary sump pump assembly 1600 with a bracket 1610that cuffs the two pumps together in accordance with examples describedherein. The bracket 1610 is shown removed from the pump assembly in FIG.16B for clarity. In this example, the volutes for each pump have anoutlet portion, which may comprise a collar 1630 and 1631 configured toattach to a discharge pipe 1660. The bracket 1610, may comprise annularportions 1612 and 1614 configured to surround the collars 1630 and 1631,respectively, thereby embracing or “handcuffing” the two pumps together.The brace can take on a variety of forms and configurations, but in someforms, the brace will extend between the two pumps, and will connect toeach pump on opposing sides of the assembly 1600. In FIGS. 16A and B,the bracket 1610 is shown to have a bridge configuration with a raisedportion 1635 between the two annular ends 1612 and 1614. This raisedbridge portion 1635 raises up so as to support a pneumatic pressure tube1620 box or housing, which can attach to a tube 1621 via a connector1622, and function as a sensor to control operations of the pumpassembly 1600.

In other configurations, however, the bracket can have a straight, flat,or planar configuration, as shown in FIG. 17. In this example, thebracket 1710 has a dumbbell like shape, with two end portions 1712 and1714 separated by a central portion 1730 that is planar with the ends1712 and 1714. Such a configuration may provide added strength andstability to the assembly, reducing the number of points of weaknessthat may be present on a bridge shaped bracket, particularly insituations where the bridge is not used to support a pressure tube.

As discussed above, some pumping systems described herein include apressure tube that can serve as a sensor to control the pumping of fluidby the system. The pressure tube can be installed or installable withrespect to the system in a variety of different configurations. In FIGS.16A and B, the pressure tube 1620 is held in between the two pumps, andsupported by a bridge shaped bracket 1610. In other configurations,however, the pressure tube can be stored within a housing, such as thehousing 1820 shown in FIG. 18. The housing 1820 can be configured toattach to the pump assembly along an outer periphery of the assembly.For example, the housing 1820 may include attachment mechanisms 1825(such as holes or protrusions) that facilitate attachment to an uppersurface of a volute of a pump assembly. In some forms, the housing 1820may have a curved shape and be configured to correspond with the contourof the pump assembly to provide a more streamlined appearance. Thehousing 1820 may include an aperture 1822 that may be configured to holdand support a pressure tube.

The present application also describes examples of sump pump assembliesthat utilize various check valve systems that control the flow of fluidout of the pump, and inhibit the flow of fluid back into the pumps. Manysystems that utilize multiple pumps are configured to discharge bothpumps through a common discharge pipe. This avoids the additional costof routing a second line dedicated to the secondary or backup pumpingunit. However, when this technique is employed, in particular withcentrifugal pumps, it may be important to utilize check valves in thedischarge lines of one or more of the pumps (and preferably both) toblock or inhibit flow from one pump back into an inactive pump unless anisolation valve like the one discussed below is used.

FIGS. 19A and 19B demonstrate why check valves are preferred in dualpump systems with a shared discharge pipe. In FIG. 19A, the dual pumpsystem 1900, which utilizes check valves, includes an active pump 1910and an inactive pump 1912 that both pump through outlets toward a commondischarge pipe 1960. In this system 1900, the flow path from each pumptoward the discharge pipe 1960 includes a check valve 1961 and 1962.These check valves allow fluid from the pump to pass out of the pump,but inhibits fluid from passing backward into the pump. Thus, in FIG.19A, fluid pumping out of the pump is directed out of the dischargepipe, and check valve 1962 stops fluid from recirculating into theinactive pipe.

FIG. 19B shows a dual sump pump system 1901 that does not utilize checkvalves. In this system, fluid from the active pump 1910 is pumped towardthe discharge pipe 1960. But because the secondary or backup pump 1912does not utilize a check valve, some or even all of the fluid pumped bythe active pipe is recirculated back through the backup pump and backinto the sump pit. Not only is this system ineffective and inefficientas the system essentially is recirculating fluid back into its ownsystem, which can result in flooding the surrounding environment and/orbe harmful to the inactive pump.

Certain aspects described herein utilize a system that employs dualcheck valves in the outward flow path of each pump. FIG. 20 shows anexample of a sump pump assembly 200 utilizing separate check valves 2024and 2025, for in the outward flow path for each pump. This situation issimilar to the one described in FIG. 19A. This dual check valveconfiguration is highly preferred for operation in pumping systems witha common discharge. However, in certain situations it may be desirableto reduce the number of check valves provided in a system withouteffecting the end result, such as by using an isolation valve.Accordingly, some aspects of this application relate to an isolationvalve (also referred to as a diverter valve) that can conserve space andcost by providing a single valve that operates to the same effect of adual check valve system. That is, the isolation valve can effectivelyallow each pump to pump fluid toward a common discharge pipe when theyare active, while also inhibiting or preventing the recirculation offluid back into an inactive pump. Such a system may be utilized to allowboth pumps to pump fluid simultaneously, thereby allowing the system tooperate in a maximum pumping mode when water levels rise to a particularlevel.

FIGS. 21-24 show various examples of isolation valves or single piecedischarge units that can be used in place of a dual check valve system.FIG. 21 shows an example of a dual sump pump system 21 with an isolationvalve 2110 that controls the flow from each of two pumps 2120 and 2130toward a common discharge pipe 2160. This isolation valve 2110 can beused to stop or inhibit the backflow of fluid through an inactive pump,while simplifying the pump system and reducing the overall number ofcomponents and connections required. As shown, the isolation valve 2100can also serve as a fork or junction that combines the two outward flowpaths from each pump into a single flow path, which in turn flows intothe common discharge pipe 2160. The embodiments with a single flap orflapper are diverters only and, in preferred forms, will still utilize adownstream check valve to ensure fluid does not recirculate. Conversely,the embodiments with two or dual flaps/flappers will preferably besufficient to prevent recirculation of fluid so that downstream checkvalves are not needed.

FIGS. 22A and 22B show a cross section of an isolation valve 220 invarious states of operation. The isolation valve 2200 has an inverted Uor Y shape, representing a fork or junction where two flow paths 2210and 2220 from two separate pumps join together. Each flow path 2210 and2220 flows through a junction toward an outer flow path 2300 in thevalve 2200, which in turn connects to a common discharge pipe 2260.Within the junction, the valve 2200 includes a flapper 2250 that rotatesabout a hinge 2252 among a variety of configurations.

In one configuration, shown in FIG. 22B, the flapper is angled to theleft, thereby blocking or obstructing the flow path 2210. In thisconfiguration, the flow path 2220 is clear to pump fluid toward thedischarge outlet 2230 while the other flow path 2210 is obstructed sothat recirculated or pumped fluid will not flow back toward the pump. Inanother configuration, the flap 2250 may move to the right, therebyallowing flow from the flow path 2210 while preventing recirculated flowback down path 2220. In still other configurations, the flapper 2250 maybe positioned in the center, thereby allowing outward flow from eachflow path 2210 and 2260.

The flapper 2250 of FIG. 22A is shown as a 2-piece configuration, havinga first flapper part 2254 on the left side configured to obstruct flowpath 2210 and a second flapper part 2255 on the right side configured toobstruct flow path 2220. When one flow path is open, a flow path mayflip a flapper part adjacent to the other flapper part. In preferredforms, this eliminates the need for having any check valves downstream.

The flapper 2250 may be configured to move based solely on themechanical forces of the pumped fluid. For example, the force of wateror other fluid pumped by the pumping system can push the flapper 2250 toan open position. The flapper 2250 can include a spring hinge thatdefaults the flapper 2250 or both flapper parts 2254 and 2255 to aclosed position when no fluid is being pumped through the respectiveflow paths 2210 and 2220. In some situations, the flapper 2250 or itscomponents can be mechanically or electronically controlled via a systemthat toggles the flap 2250 between positions. The control system maycommunicate with the pumping system, or may detect that the pumpingsystem is operating in a certain way, and thus move the flap 2250 to anappropriate position. This control feature may allow the system todetermine an ideal flapper 2250 location depending on the amount offluid being pumped from each flow path, and may allow the system tocoordinate optimum flow rates. This control may also allow the system toexecute an override to move a flapper in a situation when a particularpump is not operating or not functioning properly.

FIG. 23 shows a cross section of one example of an isolation valve 2200.Unlike the embodiment of FIGS. 21 and 22, which has an inverted U or Yshaped configuration that involves a bend or curve in the outward flowpaths from each pump, the isolation valve 2300 of FIG. 23 allows oneflow path 2320 to have a straight or linear flow path. In thisconfiguration, a first flow path 2310 coming from a first pump anglestoward the discharge portion 2330 of the valve, thereby joining flowpaths with the second linear flow path 2320. Because the first flow path2310 has a bend, the flow resistance may be increased as compared to thesecond linear flow path 2320. As such, the diameter of this pipe may beincreased to account for the flow rate drop. Alternatively, the diametermay be generally the same, but the first flow path 2310 may beconfigured to attach to a stronger pump, for example, an AC poweredpump, which may be more equipped to handle pumping through such a flowpath. In this way, the linear flow path 2320 may offer lower flowresistance to a weaker pump, for example, a DC or battery powered pump,or a smaller pump that may be used as a backup or secondary pumpingsource. In this way, the backup pump can be configured to pump fluid ina “straight shot” configuration, thereby reducing the flow resistance toa pump that may not be equipped to handle as much flow resistance.

The valve 2300 includes a flapper 2350 that rotates between positionsthat enable flow through the linear flow path 2320 while obstructingrecirculated flow through the curved flow path 2310, as shown in FIG.23. In another configuration, the flapper 2350 may obstruct the flowback into the linear flow path as fluid flows out of the curved path2310. In still other configurations, the flapper 2350 may be positionedbetween the two flow paths, thereby enabling outward flow from eachpath, for example, when both pumps are in operation.

This straight shot configuration can be used in connection with a sumppump system that has dual pumps, as described in accordance with severalof the embodiments presented herein. That is, the straight shotconfiguration may be utilized in an assembly that utilizes a primarypump to pump fluid through a primary outlet pipe or flow path toward acommon outlet pipe, and a secondary or backup pump configured to pumpfluid through a backup outlet pipe or flow path toward the dischargeoutlet pipe. The terms primary and secondary or backup here are used foridentification purposes, and may not necessarily represent functionalroles of the pumps. For example, in some embodiments both pumps may beAC powered pumps that can interchangeably execute “primary” pumpingcapabilities. In other examples, both pumps could be DC powered pumpsthat interchangeably execute primary pumping capabilities, or that areboth used redundant backups as a part of a larger pumping system.

This configuration may employ a straight shot feature so that one of thepumps can pump fluid through an outlet pipe or flow path that runsgenerally parallel with the discharge outlet pipe, and thus does notexperience a substantial pressure drop or increase in flow resistance.This straight shot feature may employ the use of an isolation valve oroutlet flow path unit as shown in FIGS. 23 or 26. Because this isolationvalve includes one straight flow path, a second flow path may include abend or curve, thereby giving rise to a pressure drop or potential flowresistance. In some situations, the bend can be gradual or angled, asshown in FIGS. 23 or 26, but in other examples, other configurations maybe used. For instance, the isolation valve may include a curved flowpath that intersects a discharge outlet pipe, or an outlet portion ofthe isolation valve at a right angle. In certain situations, the pumpingassembly will be configured so that the straight shot feature alignswith a pump (e.g., the secondary or backup pump) that has a lowerpumping power among the multiple pumps. In this way, the weaker orbackup pump can pump effectively regardless of which pump is operating.In backup outlet pipe is an extension of the discharge outlet pipe.

FIG. 24A shows another example of an isolation valve 2400. FIGS. 24B-Dshow cross sections of the isolation valve of FIG. 24A in various statesof operation accordance with other examples described herein. In thisconfiguration, the isolation valve 2400 has two linear and parallel flowpaths 2410 and 2420 that meat at a junction 2405 to converge into asingle outward flow path 2430. Positioned in the junction 2405 is a flap2450 that toggles between a position that blocks flow back into path2410 (FIG. 24C), a position that blocks flow back into path 2420 (FIG.24D), and a middle position (FIG. 24B) that allows flow out of bothpaths 2410 and 2420. In this dual flow configuration of FIG. 24B, theconfiguration of the valve 2400, the junction 2405, and the flap 2450allows both flow paths 2410 and 2420 to pump fluid at a relatively highflow rate, without experiencing substantial flow resistance and therebysuffering pressure or flow rate drops at the junction.

As noted, various forms of these isolation valves can be used inconnection with a variety of the various pumping systems or assembliesdescribed herein. In one example, a sump pump system includes a tandemsump pump unit, which in turn includes a primary pump and a secondarypump, each being arranged to pump fluid toward the discharge outlet. Thesystem also includes an isolation check valve in fluid communicationwith each of the primary pump, the secondary pump, and the dischargeoutlet. The isolation check valve operates in multiple operatingconfigurations, including a first configuration where the isolationcheck valve permits the flow of fluid from the primary pump to thedischarge outlet but obstructs the flow of fluid out from or back towardthe secondary pump. This configuration can involve the use of a flapthat pivots to close and seal a flow path toward the secondary pump, butleaves the flow path from the primary pump generally unobstructed.

The isolation check valve may also operate in a second configurationwherein the isolation check valve permits the flow of fluid from thesecondary pump to the discharge outlet but obstructs the flow of fluidout from or back toward the primary pump. This can be achieved, forexample, by rotating the flapper unit from the first position where theflow path form the secondary pump is cleared, but the flow path back tothe primary pump is obstructed and sealed.

The isolation check valve may also operate in a third configuration thatpermits the flow of fluid from both of the primary and secondary pumpsin the third configuration. This can be achieved, for example, in theconfiguration shown in FIG. 24B, where a flap is in a position thatpermits outward flow from both flow paths. Depending on the size, shape,and configuration of the isolation valve, the flow paths, and the flap,this third configuration can be arranged so that pressure drop at thejunction is minimized or otherwise arranged to allow flow from bothpumps without a substantial pressure drop or flow resistance.

The various configurations of an isolation valve or a diverter valve asdescribed herein can provide specific benefits for a multi-pump systemover a system that employs multiple separate check valves. For example,in a dual pump system with check valves, the primary pump (e.g., an ACpump) check valve will typically cycle every time the primary pump runs.This repeated cycling on and off can cause wear and fatigue to theflappers in the valves. After time, this wear and fatigue could resultin the flapper and/or the valve failing, thereby giving rise topotential flooding situations. The presently describedisolation/diverter valves, however, can inhibit these problems bylimiting, inhibiting, delaying, and/or preventing the wear and fatigueon the flapper mechanism of the valve. For example, as described above,the isolation valve can be configured so that the flapper moves to blocka flow path when fluid is flowing out of the opposing path. Because aprimary pump may run far more frequently than a secondary pump, theflapper may be in the same position (e.g., held in place horizontallylike a sewer lid either by gravity and/or water pressure), continuallyblocking the secondary flow path even after the primary pump has cycledon and off multiple times. In this way, the isolation/diverter valveflapper will not need to move each time the primary pump turns on andoff; it can simply remain in place. The isolation valve flapper may onlyneed to move away from its position blocking the secondary flow pathwhen the secondary pump turns on, which for some pumping systems may beonly quite rare. As such, the flapper of the isolation/diverter valvecan experience far fewer movements than that of a check valve, andthereby experience much less wear and tear.

This application also describes sump pump systems that employ aredundant high water switch. FIG. 25A shows an example of a sump pumpassembly 2500 with a redundant high water switch. FIG. 25B shows theassembly 2500 of FIG. 25A, with a portion of the high water switchhousing 2516 removed to show the internal components of the high waterswitch.

The high water switch 2510 is positioned at a relatively “high” level,above the pumps, and is configured to activate and communicate aninstruction or otherwise activate functionality of the assembly 2500when water rises to or beyond a level that corresponds to the switch2510. In this way, the high water switch 2510 serves as a failsafemethod for activating the pumping assembly 2500 if other meansconfigured to activate the assembly 2500 have failed. That is, wherewater has risen to the level of the high water switch 2510, it mayindicate that one or more pumps of the pump assembly 2500 (e.g., theprimary pump) was not properly activated, and will default toautomatically activate one or both pumps of the assembly 2500.Additionally and/or alternatively, activation of the high water switch2510 may suggest that a single pump operating is insufficient to keep upwith the current pumping demands. In this way, the high water switch2510 may be configured to turn on the secondary or backup pump inaddition to the primary pump when water levels have risen to the heightof the switch 2510.

FIG. 25B shows the internal makeup of the switch 2510 of FIG. 25A, anddemonstrates the redundancy features of such a device. The switch 2510includes a lower float 2512 and a secondary, or higher float 2514. Eachfloat 2512 and 2514 are configured to float on water. The high waterswitch 2510 is configured so that when the lower float 2512 rises to acertain level above a resting position, for example, because water levelhas risen to that level, the switch 2510 will activate, therebyeffecting functionality of the pump assembly 2500 (e.g., turning on thebackup pump). The higher float 2514 serves as a redundant or backupfloat in the situation where the lower float 2512 fails to operateproperly. Additionally and/or alternatively, the higher float 2514 canalso be configured to operate as a secondary switch that executesadditional or different functionality even when the lower float 2512operates properly. For example, when the lower float 2512 is activated,the pump assembly 2500 may be configured to activate a backup orsecondary pump. When the higher float 2514 is activated, the pumpassembly 2500 may be configured to operate one or both pumps at a higherrate, to communicate with another system (e.g., a second backup pumpingsystem) to begin to operate, or to execute a communication device togenerate a warning or otherwise transmit a signal to a user.

The redundant high water switch 2510 of FIGS. 25A and B are shown in ahousing 2516 that surrounds two floats 2512 and 2514 that serve as theactivating mechanisms of the redundant switch 2512. In other examples, aredundant high water switch may include other types of switches (e.g.,pressure switches, water detection switches) that operate in a similarfashion.

The present application also describes pump assemblies that include astrap handle for ease of transporting the assemblies, and/or forlowering the assemblies into a reservoir such as a sump pit. FIG. 26shows a configuration of a dual pump assembly 2600 incorporating a straphandle 2602 in addition to other features. The assembly 2600 includes afirst pump 2620 (which may be an AC powered pump) associated with afirst volute 2610 and a second pump 2530 (which may be a DC poweredpump) associated with a second volute 2612. The two pumps/volutes arecuffed together by a bracket 2660, which cuffs a discharge portion fromeach of the two pump volutes 2610 and 2612.

The discharge portions are each connected to an isolation discharge unit2650, which includes two outlet flow paths 2651 and 2652 connected tofluid outlets of each pump, and a discharge flow path 2653. Thisisolation discharge unit 2650 may be or may include any of the isolationcheck valves described above. In FIG. 26, the isolation discharge unit2650 includes a straight outlet flow portion 2652 and a curved outletflow portion 2651. In this Figure, the straight portion 2652 isconnected to the secondary pump 2630, thereby providing lower flowresistance in the discharge path of the secondary pump 2630, which mayoperate under DC power. 2600 may be removed or replaced out. Theassembly also includes a high water switch 2670, which may be similarto, and operate in a similar manner to the redundant high water switch2510 described above and depicted with respect to FIGS. 25A and B.

The assembly 2600 includes a strap handle 2602, which extends over theisolation discharge unit 2650, thereby allowing the entire assembly2600, including the isolation discharge unit 2650, to be carried as asingle assembly. The strap handle 2602 can be made from a flexiblematerial to allow the handle to be easily gripped, without making thefootprint of the assembly 2600 larger. In some examples, the handle 2602may be formed from a fabric or woven cloth material, a plastic orfiber-based material, or a rubber. The strap handle may be fastened tothe tops of the pumps by way of snaps, buttons, rivets, buckles, orother fasteners, stitching or adhesives, or the handle 2602 may bewrapped around bars or other components of the pump assembly 2600. Insome aspects, the strap handle may be removable so that certaincomponents of the assembly can be more easily removed or replaced. Thestrap handle 2602 of FIG. 23 can be used in connection with, or insteadof the handles 140 shown in the embodiment of FIG. 1A, which are shownas bar-type handles that may have a more rigid construction.

The present application also provides examples of a battery managementsystem, and related methods, that allows for pumping systems and thecontrol modules to be effectively controlled and operated by a batteryor other finite electrical power source. The system facilitatesevaluation of the power levels of the batteries, and may determinewhether a battery should be charged, replaced, and/or repaired. Thebattery evaluation system can operate differently depending on the waythe battery is being used. In one example, the battery evaluation systemcan be set up based on a 75 amp-hour deep cycle lead acid battery.

The system may evaluate the charge status of the battery, but it canalso evaluate the condition or general health of the battery. Forexample, as a battery ages, its health will likely deteriorate.Accordingly, a fully charged 8-year old battery will likely not be asuseful as a fully charged brand new battery. This is a function of wearand tear and general chemical decomposition of the battery and itscomponents.

When a pumping system is installed, the evaluation system can beconfigured to operate under an assumption that a new battery isinstalled and used. Accordingly, a processing unit of the system can beconfigured to form calculations based on an initial assumption of a newbattery, whereas additional uses and tests on the battery will be ableto consult with measurements recorded on the battery in previouslymaintained situations.

A first step for evaluation may be to charge the battery to maxcapacity, for example, the first step may involve charging the batteryfor at least 24 hours. After charging, the battery may be allowed tosettle for a certain time period (e.g., about six hours) allowing forthe removal of excess charge that occurs from the charging process. Theevaluation system can then take a voltage measurement with a simulatedmotor load. Via the processing device (e.g., a computer processor), thevoltages measured may then be stored in a database and compared to otherdata which may be stored in the database. The comparison can yieldinformation about the health and age of the battery.

For example, the evaluation system may compare voltage measurement takenat time X, where X=2 years after the original measurement on a newbattery. The evaluation system can then compare this voltage measurementwith the information in the database, which may include previousmeasurements of the battery under test, or other data for reference.Based on the currently measured voltage across the fully chargedbattery, and the other measurements or information in the database, thesystem can determine the health or capacity of the battery.

Based on the comparison results, the processor may cause a display topresent an indicator showing the status of the battery. For example, theprocessing device may cause a particular LED indicator or set of LEDindicators to operate in a particular manner so as to indicate thebattery life level. For example, a brand new battery may light an LEDassociated with a “Good” indicator, whereas a partially used battery(e.g., a battery that has been used for a few years), may light an LEDassociated with an “OK” indicator. An even further used battery towardthe end of its life may light an LED associated with “Poor” and a weakerbattery still may light an LED associated with a “Replace” or “Dead”indicator. An example of a display unit that provides the battery healthinformation is shown in the remote display panel 2800 of FIG. 28. In thepanel 2800, the series 2820 of LED indicators associated are associatedwith LED lights that indicate the “Good,” OK,” “Poor,” or “Replace”status of the battery being evaluated.

In some forms, the processing device may display the battery level via adisplay interface, for example, via a display screen that provides thebattery level as a percentage, or that presents descriptive terms (e.g.,“Good,” “OK,” “Poor,” “Replace,” etc.). And in some embodiments, theprocessing device may operate in connection with an audible alarm thatgenerates an audio signal instead of, or in addition to the generationof these visual indicators.

As a battery ages (e.g., over a period time, such as a few years), thevoltages measured under load will reflect lower voltage values as aresult of the chemical characteristics of the battery degrading. Thebattery evaluation system is thus configured to perform repeatedperiodic voltage measurements. For example, measurements may be repeatedabout once a month, but in some situations depending on the type ofbattery and the battery's age, this measurement can be taken more orless frequently. In some forms, this involves subjecting the batter to aload to test battery parameters; however, in a preferred form, thesystem will use a load-free or no load battery test. For example, in oneform, the system is set up based on a seventy-five amp-hour deepdischarge lead acid battery. When a system is installed the unit assumesthat a new battery is installed. The system's first step is to chargethe battery for 24 hours. The battery is then allowed to settle for sixhours to remove excess charge from the charging process. An open circuitvoltage measurement is made. The voltages measured are compared tostored data and a battery health LED is illuminated to show the statusof the battery. In one form, the system will signal the following:

-   a new battery will illuminate a >4 Hr LED;-   a worn batter (e.g., a battery that is a few years old) will    illuminate a 2-4 Hr. LED;-   a well-used battery (one considered more used than a worn battery)    will illuminate a 1-2 Hr. LED; and-   a weak battery (one more worn than a well-used battery) will    illuminate the REPLACE LED.

As the battery ages, over a period of years, the measured open circuitvoltages will reflect lower voltages as the chemical characteristics ofthe battery degrade. In a preferred form, the battery voltagemeasurement is repeated once a month. The battery must meet the “fullycharged” criteria (>13.9V & <0.75 A) before the measurement isperformed. The capacity of a fully charged battery is shown byilluminating an LED scale. Charging is done automatically when the pumpis not running and charge current is adjusted so as not to damage thebattery. When the DC pump is run, the control measures the current usedand the amount of time the motor runs. Amp-hours consumed arecalculated. The amp-hours used are compared to the latest battery healthcapacity measurement. An estimate of projected run time is made and theappropriate run time LED is illuminated according to the above. As adepleted battery is being charged, the control keeps track of the chargebeing added to the battery so the status of available run time iscurrent. In a preferred form, a newer battery, fully charged, will show6 hours or more run time. A poor battery fully charged may only show 1-2hours and a newer battery will likely be needed after 4-5 hours of useof a poor battery.

As noted, it can be most efficient if the voltage measurements are takenon batteries that are fully charged (e.g., the battery has been chargedfor at least 24 hours before performing the measurement). The capacityof the battery can be shown by a different indicator that indicates thebattery life (e.g., see interface 2810 in FIG. 28). The evaluationsystem can also be configured to automatically charge a pump when it isnot running. The system can also be configured to change the current, orallow a user to change the current so that the battery does not becomedamaged.

When a DC operated pump is running, certain features of the evaluationsystem can be used to measure the current used and the amount of timethat the pump motor is running. In this way, the evaluation system cancalculate and store information pertaining to the amp-hours used by thepump. This value of amp-hours used can be compared to the latest batteryhealth capacity measurement values. Based on this calculated value, theevaluation system can estimate the projected run time of the pump andcommunicate a value to a user, for example, by lighting a particularLED, displaying information on an interface, sounding an alarm,generating a notification, or other similar techniques. The calculatedvalue can represent, for example, the expected run time of the batteryoperating at its current rate without the need for further charging. Asa depleted battery is being charged, a control for the evaluation systemcan keep track of the charge being added to the battery and update thecurrent run time of the battery accordingly.

In some examples, a new battery, fully charged will show a run time of 6or more hours. An older battery showing a poor status, even when fullycharged may only show a run time of 1-2 hours. In some examples, thenewer battery, after operating for 4-5 hours, may still show 1-2 hoursof available run time. The panel 2800 of FIG. 28 also includes a display2810 that provides information pertaining to the current anticipated runtime of the battery. In the panel 2800, the series 2810 of LEDindicators associated are associated with LED lights that indicate theanticipated run time of a pump operating under current operatingconditions based on the current status of the battery. The calculatedrun time can be based on features such as the current operating rate ofthe pump, the health of the battery, and the current charge level of thebattery, for example.

FIG. 27A shows a dual pump assembly 2700 with two pumps 2701 and 2702,an air switch 2720 and a one-piece discharge pipe 2710. The air switch2720 includes a pressure tube housing that attaches to the pump assemblyabout an exterior side of one of the pumps. The air switch can be or caninclude the air switch depicted in FIG. 18 and described above. Theone-piece discharge pipe 2710 can be, or can include the isolationvalves or discharge units described above with respect to FIGS. 21-24Dand 26. For example, the assembly 2700 may include a one-piece dischargepipe unit that includes the straight shot portion and the curved portionspecifically depicted in FIGS. 23 and 26. In other examples. Byemploying a one-piece unit 2710, the assembly 2700 is “site ready” for aquick and easy installation. That is, the assembly 2700 can beconfigured to hook up to a discharge pipe at a single location (e.g.,via the discharge outlet 2730).

In the embodiment of FIG. 27A, the two pumps 2701 and 2702 are cuffedtogether via a bracket 2715, which can operate in manner similar to thatof bracket 1610 shown with respect to FIGS. 16A and B, albeit with adifferent configuration. The bracket 2715 is shown in more detail inFIG. 27B, separate from the pump assembly 2700. In this example, thebracket 2715 includes opposing annular portions 2712 and 2714 configuredto surround collars of the two pumps 2701 and 2701, thereby embracing or“handcuffing” the two pumps together. The bracket 2715 is shown to havea bridge configuration with a rounded or domed raised portion 2735between the two annular ends 2712 and 2714. Offset from one of theannular portions 2714 is a pressure tube housing support 2712, which isused to support the pressure tube housing of the air switch 2720, asshown in FIG. 27A. In some forms, the pressure tube housing may have theconfiguration of the housing 1820 shown in FIG. 1820, whereby thehousing 1820 attaches to the housing support 2712 by way the connectionmechanism 1825.

FIG. 28 shows a remote display panel 2800 for a pumping system. Thepanel 2800 provides system status and water level information as itpertains to a pump assembly. The panel 2800 includes a variety of LEDlights that are associated with indicators. For example, the panel 2800includes a battery charge level section 2810, which includes a series ofLED lights that are associated with indicators related to the “Hours ofProtection.” These indicators may work in conjunction with the batteryevaluation system described above. As the pump continues to draw powerfrom the battery and the charge diminishes, the panel 2800 will lightdifferent LED lights in the Hours of Protection section 2810 tocorrespond with the currently calculated expected battery run time.

The panel 2800 also includes a section 2820 configured to display thehealth of the battery. The series 2820 of LED indicators associated areassociated with LED lights that indicate the “Good,” OK,” “Poor,” or“Replace” status of the battery being evaluated. As described above,this battery health level is different from, the battery charge statuslevel indicated in section 2810, but may be used as a basis fordetermining the hours of protection displayed in section 2810.

The battery health level can be monitored, as described above, byperiodically performing a series of steps that include: (1) charging thebattery for a predetermined minimum time period is sufficient to fullycharge the battery; (2) measuring a voltage across the battery (e.g.,via a simulated motor load); (3) comparing, with a processor, themeasured voltage with information in the data store; (4) calculating thebattery health value based on the comparison of the measured voltagewith the information in the data store; and (5) generating a signal viathe interface 2820 that indicates the battery health value.

The data store can be an electronic storage device that is incommunication with the panel 2800 or other components of the relatedpump assembly. The data store can include pre-loaded information, suchas a look-up table, that corresponds a voltage reading with a particularbattery health level. The data store can also be periodically updatedwith measurements taken according to the periodically performed method,so that the battery health level is based at least in part on themeasured voltage for that battery during previously performedmeasurements. The battery charge value may be configured to approximatea length of time that a pump can operate on the power provided currentbattery without further charging.

As noted above, the battery health level can be used as a part of thecalculation to determine the hours of operation displayed in interfacearea 2810. For example, a brand new battery having a “Good” health levelthat is determined to be half-way depleted of charge may display an LEDassociated with the indicator associated with 2-4 hours. Conversely, anolder battery having a “Poor” health level may indicate only a 1-2 hourlevel when the battery is determined to be fully charged.

The panel 2800 also includes a display area 2830 that providesinformation pertaining to the water level in the basin. In this region2830, the panel will light up a certain LED light or series of LEDlights to indicate the amount of water currently in the basin or pumpassociated with the pump assembly. Using sensors associated with thepump assembly (including a number of the sensors described herein), thepanel 2800 will determine a detected water level, and generate a displayon interface region 2830 that presents that water level to a user.

The display panel 2800 may also include a power/status section 2840 thatidentifies which pumps, if any, of the pump system are currentlyoperating. For example, the LED associated with the “Primary Pump”indicator will light if the primary pump of the system is operating, theLED associated with the “Backup Pump” indicator will light if the backuppump of the system is operating, and an LED associated with a “TurboMode” indicator may light if both pumps are operating. In some examples,a user may be able to control which pumps are operating via the panel2800, for example, by activating buttons or other input mechanisms.

The display panel 2800 also includes a variety of functional operators,which can be a push-button feature that generates functionality whenpressed by a user. In particular, panel 2800 includes a test operator2850, which generates a test to assure that the system is operatingproperly when pressed. In some configurations, the panel 2800 or otherobjects associated with the panel 2800 may be configured to generateaudible sounds and warnings, as described herein. Accordingly, the panel2800 also includes a mute operator 2860, which can be configured tosilence or mute all audible sounds when activated by a user.

FIG. 29A is a top view of an integrated pump controller 2900 thatoperates a battery management system as described above. The controllermay 2900 may be attached to, or rest upon a power supply, such as abattery or other DC power source that supplies backup power to a pumpingsystem. The controller 2900 may also include a louvered portion 2910that allows air to flow to the processing equipment, which can helpprevent the control unit from overheating.

As shown in FIG. 29A, the controller 2900 includes an operatinginterface with a series of operators that can be configured to execute avariety of different functions. For example, the interface can include areverse battery indicator 2912 that alerts users when the battery isconnected to the system wrong or backwards. If the battery is accidentlyconnected wrong (e.g., with the wrong polarity), then the reversebattery (or incorrect battery connection) indicator 2912 is displayed.While in the preferred embodiment this incorrect battery connectionsignal 2912 includes a displayed signal, such as a light, it should beunderstood that in alternate embodiments the reverse battery indicatormay include (in addition to or in lieu of the visual display) an audiblealarm to warn the user the connection is incorrect (preferablyimmediately).

A battery test/safety reset operator 2914 can perform a test on thebattery, for example, determining a current state or health level of thebattery and display that value on the interface. The battery test/safetyreset operator 2914 can also be configured to perform a safety reset ofthe pumping system. For example, when a tripping deice determines that athermal load on a portion of the circuit has exceeded a safe operatingtemperature and trips the circuit, the safety reset button can beoperated to reactivate the circuit (e.g., reset may reset the thermaloverload protector).

A mute operator 2916 can be configured to silence all audible alarmsgenerated by the controller 2900 or associated units. In some examples,the mute operator can be pressed in advance of an alarm sounding and canhave the effect of silencing all alarms that may potentially soundwithin a given time period. For instance, if a user will be working onor around the controller 2900 for a certain time period and wishes notto be distracted by an alarm, the user may press the mute operator 2916to deactivate or mute all audible alarms in advance for a predeterminedtime period. The mute operator 2916 may serve to mute all alarms for apredetermined time period with each press. For example, the controller2900 may be configured so that one press of the mute operator 2916 willserve to mute all alarms for one hour. The controller 2900 may allow themute operator 2916 to be pressed multiple times to extend the mutedperiod as desired by the user. For example, the controller 2900 may beconfigured to allow the mute operator 2916 up to eight times to mute allalarms in advance for up to eight hours.

The display interface may also include the system test operator 2918,which can be configured to effect the performance a test on the pumpsystem to assure that certain features of the system are able to operateas expected. The system test can be configured to operate the primarypump and the backup pump to ensure that the pumps turn on and operate asexpected, and that there are no clogs or other obstructions.

The control unit 2900 also may be connected to a display panel, such aspanel 2800 as shown with respect to FIG. 28. In other embodiments,rather than (or in addition to) being connected to a display panel, thecontroller 2900 may communicate wirelessly with a remote device orseries of devices to provide the information that could be displayed onthe panel. For example, the controller 2900 may communicate with amobile electronic device (e.g., a smart phone, tablet computer) or othercomputing device via the Internet, a wireless network, or a cellularnetwork. The device can operate an application that will allow the userto receive information and affect control functionality that mayotherwise be available via the display panel (e.g., panel 2800). In someforms, the remote device operating the application may be capable ofperforming additional functionality and displaying additionalinformation beyond that available by a panel.

FIG. 29B is a rear view of the integrated pump controller 2900 andbattery management system of FIG. 29A. As shown, the controller 2900includes a variety of connection ports that allow a user to connect avariety of components to the controller. For instance, the controller ofFIG. 29B is shown having an AC power in cord 2920 that provides AC powerto the controller, for example, via a 120-volt AC outlet or the like.The controller 2900 also includes a power supply line 2921 that deliverselectrical power from a battery associated with the controller 2900 to aDC powered device, such as a DC powered sump pump. An AC powered line2922 provides AC electrical power to another electrically powereddevice, such as an AC powered sump pump. A remote display line 2923forms a communication line between the controller 2900 and a displaypanel, such as panel 2800 shown in FIGS. 28 and 29A. An air switch line2925 communicates with an air switch associated with the pumping systemand facilitates the controller 2900 to effect, cease, or modify theoperation status of the pumps of the pumping system. The backup floatswitch line 2924 communicates with the controller and serves as aredundant backup to assure that the pump operates as desired even whereissues may arise with other primary sensors or operating equipment.

FIGS. 32A and 32B provide another embodiment of a controller/batteryassembly 3200 that can be used in connection with a variety of thepumping systems described herein. The assembly 3200 includes a battery3202 or DC power supply, which can be stored, for example, in a batteryhousing. A controller 3201 rests upon the battery 3202, and may beattached or attachable thereto. The controller 3201 has a connectionpanel 3210 that allows the assembly 3200 to connect and communicate withvarious equipment of the pumping system.

FIG. 32B shows a head on view of the panel 3210 of the pumping system.The panel 3210 comprises a variety of outlets for attachments to varioussensors and devices. A 120-volt AC input 3211 allows the controller 3200to receive electrical power from an AC power source, which AC power canbe used to charge the battery 3202. An AC pump outlet 3224 allows anelectrical cable to connect with an electrical device (e.g., an ACpowered pump) and provide AC power to the device. In some formats, theAC pump outlet 3224 may provide up to four amps of electrical current. ADC pump power outlet 3214 provides DC electrical power from the battery3202 to a DC powered pump, such as a 12-volt DC pump, which may serve asa backup pump to the pumping system.

The panel 3210 also includes a security alarm port 3212, which canconnect to one of various security devices including speakers or soundgenerating equipment, lights or display equipment, and/or communicationdevices that can send security signals to other remote devices (e.g.,text messages). The panel 3210 may also include a speaker and/or audiblealarm system that generates warning sounds in the event of certaindetected events (e.g., high water warnings, pumps not operating, batterylevel low, etc.) In this manner, the panel 3210 may include a mutebutton 3218, which serves to silence any such alarm, and a test button3219, which allows the user to test the alarm signal to ensure that itis operating properly.

The panel 3210 may also comprise one or more DC pump fuses, including aprimary DC pump fuse 3215 and a spare or backup DC pump fuse 3213.Communication ports 3216 allow the controller 3201 to communicate withvarious display equipment, such as display panels, monitors, or otherinterfaces. The communication ports 3216 may also enable communicationwith other equipment or communication devices, such as an internetrouter, a telephone line, a cellular network, or the like. The panel3210 may include ports for connecting to various sensors, such as awater sensor port 3223 that communicates with a sensor that monitors thewater level in a sump pit, and a back-up float switch port 3222 thatcommunicates with a backup float switch that serves as a redundantswitch to any float switches associated with the pumps of the pumpingsystem. Vent holes 3221 on the panel 3210 allow for air flow into thecontroller 3201, which helps inhibit overheating. The panel 3210 mayalso include a warning system that includes a reverse polarity warninglight 3217, which may light up or blink when polarity between thebattery and the controller and/or pumping systems is not configuredproperly, thereby warning the user to correct the issue beforeinitiating the supply of power.

Examples described in this application may utilize various techniquesfor controlling operation of the pumping devices. For instance, sumppump water level can be controlled by a float activated switch. As thewater level in the sump rises to a predetermined level, a floatingdevice imposes a change in the state of an electric switch, which switchin turn activates a pump to remove water and reduce the water to a lowerlevel. This level control is normally achieved through hysteresis builtinto the float mechanism. Many sump pump failures can be traced to afailure of the switch. Accordingly, some aspects described herein relateto an electronic tilt switch that can be used in lieu of a float switchor other device.

The electronic tilt switch utilizes high volume accelerometertechnology, such as those used in portable electronic devices, to createa switch that can control the operation of the pumping system. Anexample of such an electronic tilt switch is shown in FIGS. 30A and 30B.In FIG. 30A, the tilt switch 3000 takes advantage of a 3-axisaccelerometer of the sort that may be used in smart phones or othersimilar devices. The tilt sensor 3000 can be secured to a fixedstructure, such as discharge pipe 3050. The tilt switch 3000 includes afloat 3020 and a hinged housing 3010. The float 3020 has anaccelerometer, which can be located, for example, within a cavity 3022of the float. The accelerometer is used measure the tilt angle of thefloat. Thus, when the water level within the sump rises to the level ofthe tilt sensor 3000, the float 3020 will rotate with respect to thehinge 3010, and the accelerometer will detect a change, and communicatewith a remote circuit board via a cable 3060, or another communicationmode (e.g., wireless communication). The supporting circuit board can belocated remote to the tilt sensor 3000. That is, in some embodiments,the accelerometer may be in the float 3020, and the remaining supportingcircuitry is located remote from the accelerometer, such as in a controlunit.

FIG. 30B shows the tilt switch 3000 from a rear view, where the float3020 is at its highest position, having pivoted about the hinge 3010. Inthis view, the water level in the sump has risen beyond the location ofthe tilt switch 3000, thereby causing the float 3020 to pivot upwards byan angle θ. The tilt switch and/or the supporting circuitry (which maybe within or remote to the tilt switch) can be configured to effectoperation of a pumping device when the accelerometer detects that thefloat has pivoted by an angle θ, thereby representing a predeterminedwater level in a sump pit.

FIG. 31 shows an example set up of a sump system 3100 utilizing the tiltswitch 3000 with an accelerometer of FIGS. 30A and B. The system 3100includes a sump pump 3110 within a sump 3105, supplied with electricalpower via a power cord 3115. The tilt switch 3000 is attached to adischarge outlet 3150. The tilt switch 3000 communicates with a controlbox 3120 via the power cord 3060. The control box 3120, powered via apower cord 3125, can include the various power switching electronics,which can include a single load driving output, such as a triac, a zerocrossing device, micro-processor transformers/dropping resistors, adiode bridge, or the like, within a housing. In some examples, thecontrol box 3120 may include or be with associated LED's, alarms, andpossible telephone dialer that provide notifications to a user. With asingle electronic tilt switch 3000 the water level will be detected by apredetermined angle θ, as measured by the accelerometer and relatedequipment inside the tilt switch housing 3010.

In one example of operation, when the tilt sensor 3000, via theaccelerometer, detects a level change that is greater than apredetermined value (e.g., angle θ), the accelerometer will communicateto the control box 3120 to change the state of the triac, therebyeffecting operation of the pump 3110. As the water level in the sump pit3105 drops, the angle θ will be monitored by the accelerometer. Thechange in the angle θ over to time can be calculated by a microprocessorwithin the control box 3120 to establish an appropriate off level forthe pump. In some configurations, if the triac can be configured toactivate an alarm function to notify a user if the water level does notdrop at a predetermined rate, or to a certain level within apredetermined time. In some forms, the system can be configured toactivate a second alarm function if the water level continues to rise.For purposes of redundancy or for controlling additional pumps multipleelectronic tilt switches could be employed.

Various embodiments described herein include cords that supplyelectrical power to the pump assembly. The cords may serve to provide ACpower to an AC pump, or to provide a charge to a battery of a DC pump,or to connect a DC pump to a battery. In some examples, the variouscords of the assembly will be configured so that all cords form the samelength. This cord length matching provides users with assurance that adevice is installed properly. Some examples of the pump assembly willinclude cord management systems that facilitate winding or wrapping ofcords around the pump assembly or other objects associated with theassembly. The cord management systems may include spring or motor drivencord retraction mechanisms that facilitate winding of the cord about thepump.

Certain examples described herein describe pumps that utilize topsuction functionality. That is, the pumps draw in fluid to be pumpedfrom an upper location (e.g., above the volute), and draw in the fluiddownward rather than by sucking the fluid upward through a bottomportion of the pump (e.g., from below the volute). This top suctionfunctionality creates a self-venting feature that inhibits air-lockingproblems that can occur in bottom suction devices. As a result, the topsuction functionality allows for the pumping apparatus to operatewithout applying vent holes in the discharge pipe (which is oftennecessary for bottom suction devices), or other venting mechanisms.

The presently described technology has several applications for use. Forexample, the presently described systems and applications can be used inresidential sump pits (which are employed in a majority of homes withbasements); in rental properties (where the tenants may not be aware ofthe sump system); in vacation homes (where the occupants may not bepresent during a high water event); and/or in other locations whererising water could cause damage (crawl spaces, stair wells, etc.).

The present disclosure presents embodiments of tandem sump pumpassemblies that refer to primary and secondary pumps. In some aspectsthe primary pump will be an AC powered pump and the secondary pump willbe DC powered. However, in some embodiments both pumps will be ACpowered, and in other aspects, both pumps could be DC powered. Dependingon the intended use, all embodiments described herein, and allreferences to AC pumps and/or DC pumps could be substituted for an AC/DCpump unless the context makes clear otherwise.

Thus, in view of the above disclosure, it should be understood thatnumerous concepts are disclosed herein and intended to be coveredherein. For example, in one form and as shown in final FIG. 33, aback-up pump system is disclosed having a primary AC pump and asecondary DC pump, with the primary AC pump having a primary switch foroperating at least one of the pumps (e.g., a solid state switch), andthe secondary DC pump having a secondary switch for operating at leastone of the pumps. We have used similar numbering to that show in FIGS.1A-G, 16A-B, and 18, but adding the prefix 33 to distinguish oneembodiment from the others. The system includes a back-up battery forpowering the secondary DC pump when regular power conditions areinterrupted (e.g., power outages, unplugged AC cord, other loss of mainspower supply, etc.). A primary controller is electrically connected tothe pumps for operating same, and a secondary controller, discrete fromthe primary controller, and electrically connected to at least one ofthe pumps to operate the at least one of the pumps when the primarycontroller malfunctions or fails.

In some forms, the solid state primary switch may include a pneumaticpressure transducer sensor that utilizes pressure differentials todetermine when one or more of the pumps should be operated. The primarycontroller may also include a processor programmed to activate theprimary AC pump when the pneumatic pressure transducer indicates that athreshold fluid level has been reached. The processor may be programedto activate the secondary DC pump when the regular power conditions areinterrupted and when the threshold fluid level has been reached. Inaddition or even alternatively, the processor may be programmed toactivate the secondary DC pump when the primary AC pump is not loweringthe fluid level at a sufficient rate or in a sufficient amount of time.In some forms, the primary controller will include a processorprogrammed to perform a battery health check.

As mentioned above, some embodiments will have a battery chargingcircuit electrically connected to the back-up battery for charging thebattery and regular power conditions are present, and having a batteryhealth monitoring circuit for monitoring battery health. The batteryhealth monitoring circuit may include a display for displaying indiciaindicative of the battery health and an alarm for alerting a user to aproblem with the battery based on the monitored battery health. The termalarm is used broadly to mean any type of audible alarm (buzzer,speaker, siren, etc.), visual alarm (e.g., light, flag, display, etc.)and/or an electronic message alarm (e.g., text, app notification,auto-call or voice message, etc.). Similarly, the term display is usedbroadly to mean any type of light, digital display (e.g., LED display,LCD display, touch screen, plasma display, numeric display, etc.),analog display, and/or a mechanical indicator (e.g., flag, indicator,etc.).

In a preferred form, the primary controller includes a communicationdevice for transmitting notifications about the pump system to a user.The communication device may include a transmitter or transceiver forconnecting the primary controller to a wireless network to transmit thenotification via the network. A transceiver is preferable to allowtwo-way communication and user interaction with the pump system to getinformation from the pump system (e.g., real-time status, diagnosticanalysis, historical data, such as performance data, etc.).

In some forms, the pumps system is connected to a discharge pipe via oneor more check valves. However, in other forms, the primary AC pump andsecondary DC pump are connected to a diverter valve that diverts fluidflowing from one of the pumps toward a discharge pipe that the pumpsystem is connected to and hinders fluid from backflowing orrecirculating back into the other pump (e.g., the diverter prevents onepump from pumping fluid back or backwards into the other pump to preventflooding, etc.). In a preferred form, the diverter valve includes firstand second inlets, one common outlet and a diverter body positionedbetween the inlets, the first inlet being in fluid communication withthe primary AC pump and the second inlet being in fluid communicationwith the secondary DC pump, and the diverter body being movable between:a first position wherein the diverter body blocks the second inlet andallows fluid to flow from the primary AC pump to the common outlet whilehindering fluid flow into the second inlet; and a second positionwherein the diverter body blocks the first inlet and allows fluid toflow from the secondary DC pump to the common outlet while hinderingfluid flow into the first inlet. The first fluid passage extendingbetween the primary AC pump and the common outlet may include a curve orbend, and the second fluid passage extending between the secondary DCpump and the common outlet may form a generally linear fluid passagewhich allows the second fluid passage to provide less fluid resistancethan the first fluid passage to allow the secondary DC pump to operatemore efficiently since it is powered by the battery and not an AC powersupply. In some instances it is preferable to have the AC pump side ofthe system deal with plumbing bends and turns that cause loss or greaterfluid turbulence and inefficiencies since AC power seemingly isavailable for extended periods of time compared to the DC power providedby a battery (e.g., batteries have battery life and it is desirable tosetup the system to maximize efficiencies that conserve the batterypower life). In the forms illustrated, the curve or bend of the firstfluid passage is between 45°-90° (e.g., the bend in the plumbing orpiping from the AC pump to the outlet pipe) and the second fluid passageis coaxially aligned with the discharge pipe (e.g., a straight orstraighter shot).

Also disclosed herein is a pump system having a connector for connectingthe primary AC pump to the secondary DC pump so that the pumps may bemoved or placed together as an assembly. In the form illustrated in FIG.33, the connector 33610 is a coupling that has a first interface 33614for aligning with a first AC pump 33130 outlet and a second interface33612 for aligning with a second DC pump 33120 outlet so that the pumpsmay be connected to one another and moved or placed together as anassembly. A raised arch connects the first and second interfaces 33614,33612 of the coupling 33610. The first interface 33614 is connected tothe first AC pump outlet via a first fastener 33631 and the secondinterface 33612 is connected to the second DC pump outlet via a secondfastener 33630. The first AC pump outlet and second DC pump outlet eachhave internal female pipe threading (FPT) and the first fastener andsecond fastener are threaded sleeves each having male pipe threading(MPT) on one end that mates with the FPT of the first AC pump outlet andsecond DC pump outlet, the fasteners further each having a flangeportion that engages respective portions of the coupling to secure thecoupling to the pumps and the pumps to one another. In the formillustrate in FIG. 33, the flange has flat edges to form a nut-typethreading that a wrench can be used with and/or engage to tighten thesleeve to the pump and clamp the coupling between the sleeve and thevolute. Seals (e.g., rubber sealing rings, washers, etc.) may also besued to improve this connection. In the form illustrated in FIG. 33, thecoupling further includes a portion for connecting at least a portion ofthe pneumatic pressure transducer sensor to in order to position the atleast a portion of the pneumatic pressure transducer in a desiredposition in relation to the pumps. The portion protrudes out from one ofthe interfaces of the coupling (e.g., 33612) to position a hollowhousing 33820 of the pneumatic pressure transducer sensor proximate theside wall of one of the pumps (e.g., DC pump 33120).

In other forms mentioned above, the connector may be a first matingmember connected to the primary AC pump and a second mating memberconnected to the secondary DC pump and the first and second matingmembers mate with one another to connect the pumps to one another. Forexample, the first mating member may be one of a male or female matingstructure and the second mating structure the other of a female or malemating structure so that the mating members interconnect with oneanother to connect the pumps together. In one earlier form, the voluteswere formed with such structures to interconnect the volutes and, thus,the pumps to one another.

The connector may also include other items that also help connect thepumps to one another. For example, in FIG. 33, the connector is also amember that extends from a top or side surface of the primary AC pump toa top or side surface of the secondary DC pump to connect the pumpstogether. In the form illustrated, the member is a handle 33140 thatinterconnects the pumps so that they can be carried or placed as aconnected assembly. In some forms, two such handles have been shown madefrom metal and interconnecting the top of the pumps. In other formsillustrated herein, this form of connector has been a fabric strap.Regardless of its ultimate form or shape, it may be helpful to usemultiple forms of connectors in order to securely connect one pump tothe other so that they travel and place well. For example, having afirst connection between the lower portions of the pumps (e.g., the pumpoutlets, e.g., volute outlets) and a second connection between the upperportions of the pumps (such as the handle interconnecting the tops ofthe pumps) helps form a stable connection between the pumps and one thatallows for easy carry and placement. AC power cord 33104 and DC powercord 33102 are also illustrated in FIG. 33.

In addition to the above and as illustrated in FIG. 33, the plumbing orpiping of the pumps forms yet another connector that connects the pumpsto one another. This PVC piping forms a cross-over connection betweenthe two pumps that establishes yet another connection point or portionbetween the two pumps. In a preferred form, the handle will extend overthe top of this piping in order to encourage the connected pump assemblyto be carried by the handle and not the piping or plumbing. In the formillustrated in FIG. 33, each pump has a check valve connected downstreamof the pump outlets (e.g., volute exits), and preferably downstream ofthe coupling that interconnects the volutes. Then the cross-overplumbing or piping connects the respective check valves to a commonoutlet pipe which can be connected to a common discharge pipe of thesystem via a simple rubber sleeve connector (or coupling) connected tothe discharge pipe and the common outlet pipe via hose clamps or thelike. The check valves prevent either pump from pumping fluid backwardsinto the other pump (e.g., recirculating or backflowing fluid into theother pump). However, in alternate embodiments similar to thosediscussed above, the pump assembly could be configured with a singleisolation valve (e.g., diverter valve) to be used in lieu of the dualcheck valve configuration.

It should be understood that the embodiments discussed herein are simplymeant as representative examples of how the concepts disclosed hereinmay be utilized and that other system/method/apparatus are contemplatedbeyond those few examples. For example, while an AC pump and DC pumpsystem is described as preferred, it should be understood that thisdisclosure contemplates using two AC pumps or two DC pumps, etc. Inaddition, it should also be understood that features of one embodimentmay be combined with features of other embodiments to provide yet otherembodiments as desired. Similarly, it should be understood that whilethe system/method/apparatus embodiments discussed herein have focused onsump pump systems, other uses of the solutions presented herein arecontemplated, such as the use of other type of pumping devices.

What is claimed is:
 1. A pump system comprising: a primary AC pump; acontrol unit having a wireless communication circuit or module; and aback-up battery for powering the control unit; wherein the wirelesscommunication circuit or module is configured to communicate via aprimary wireless connection and communicate via a secondary directwireless connection when the primary wireless connection is unavailable.2. The pump system of claim 1: wherein the primary wireless connectionis an internet connection and the control unit detects internet access,and wherein the wireless communication circuit or module communicatesvia the secondary direct wireless connection when no internet access isdetected.
 3. The pump system of claim 1 further comprising a buttonconfigured to establish the direct wireless connection.
 4. The pumpsystem of claim 1 further comprising a backup DC pump.
 5. The pumpsystem of claim 1 wherein the wireless communication circuit or moduleis configured to communicate via one of Wi-Fi, Bluetooth, Bluetooth LowEnergy, Near Field Communication, Radio Frequency, Infrared, and Zigbee.6. The pump system of claim 1 further comprising a remote electronicdevice, wherein the remote electronic device is configured to receive anotification from the control unit via the Internet and via the directwireless connection.
 7. The pump system of claim 6 wherein the remoteelectronic device is at least one of a smartphone, a tablet and a mobilecomputer.
 8. A method of monitoring a pump system comprising: detectinga value, the value representing at least one of a water level, a lowbattery level, a battery fault, and a pump fault; transmitting anotification based on the value to a remote electronic device via aninternet connection; and transmitting a notification based on the valueto the remote electronic device via a direct wireless connection.
 9. Themethod of claim 8 further comprising detecting access to the internet.10. The method of claim 8 further comprising pairing the pump system tothe remote electronic device.
 11. The method of claim 10, whereinpairing the pump system to the remote electronic device is done inresponse to detecting the pressing of a button.
 12. A method formaintaining communication with a pump comprising: providing a pumphaving a controller with a communication circuit for communicating witha remote electronic device over a primary communication network and overa secondary communication network when the primary communication networkis not available; communicating via the controller and the remoteelectronic device over the primary communication network when theprimary communication network is available; and communicating via thecontroller and the remote electronic device over the secondarycommunication network when the primary communication network is notavailable.
 13. The method of claim 12 wherein the primary communicationnetwork comprises a wireless LAN having a router and the secondarycommunication network comprises a software enabled access point (SoftAP)or virtual router network and the method further comprises:communicating via the controller and the remote electronic device overthe wireless LAN when the wireless LAN is available; and communicatingvia the controller and the remote electronic device over the SoftAP orvirtual router network when the wireless LAN is not available.
 14. Themethod of claim 13 wherein the SoftAP or virtual router network isformed by the controller serving as a wireless hotspot and communicatingvia the controller and the remote electronic device over the SoftAP orvirtual router network when the wireless LAN is not available comprisesconnecting the pump controller as a client of the wireless hotspot. 15.A wireless communication module for a pump comprising: a computerreadable medium for storing network information; a wireless transmitter;a wireless receiver; an input; and a processing element adapted toreceive the network information from the computer readable medium andoperate the wireless transmitter and receiver to connect to a wirelessnetwork, the processing element further adapted to operate the wirelesstransmitter and receiver to form a hot spot in response to actuation ofthe input.
 16. The wireless communication module of claim 15 wherein thewireless transmitter and wireless receiver are a wireless transceiver.17. The wireless communication module of claim 15 wherein the wirelesstransmitter and wireless receiver are a WiFi module.
 18. The wirelesscommunication module of claim 15 wherein the input is a button.
 19. Thewireless communication module of claim 15 wherein the processing elementis further configured to transmit commands to a pump control unit.